ES2690097T3 - Apparatus for the formation of an ophthalmic lens based on a lens precursor - Google Patents

Abstract

An apparatus for forming an ophthalmic lens based on a Lens Precursor (1700), the apparatus comprising: a light source (520) capable of emitting actinic radiation; a homogenizer (530) positioned to receive light from the light source and provide a more uniform intensity of light than the light received; a spatial light modulator (510) that reflects at least a portion of the light provided by the homogenizer (530); a converging lens system that converges the light reflected by the spatial light modulator (510); a mold part (580) comprising a transmissive lens forming surface of sufficient convergent light reflected by the spatial light modulator (510) for comprising actinic radiation; a container (590) for containing reactive mixture around the lens-forming surface in an amount in excess of an amount required to form the Lens Precursor (1700); a housing location where the mold part (580) can be placed such that the fluid chemical residue (1745) can flow through the near surface region of the Lens Precursor (1700); and a fixation radiation source (1460), in addition to the light source capable of emitting actinic radiation, sufficient to fix the unreacted and partially reacted monomer comprising the Lens Precursor (1700) to form the ophthalmic lens based on Lens Precursor (1700).

Description

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DESCRIPTION

Apparatus for the formation of an ophthalmic lens based on a lens precursor FIELD OF USE

This invention describes an apparatus for the manufacture of ophthalmic lenses.

Background of the invention

Ophthalmic lenses are often made by molding, in which a monomer material is deposited, in a defined cavity between optical surfaces of opposite mold parts. Multi-part molds used to make the hydrogels in a useful article, such as an ophthalmic lens, may include, for example, a first molding part with a convex part that corresponds to a posterior curve of an ophthalmic lens and a second mold part. with, a concave part that corresponds, with a frontal curve of the ophthalmic lens. To prepare a lens, using such mold pieces, an uncured hydrogel lens formulation is placed between a disposable plastic mold curve front part and a disposable plastic rear mold curve part.

The front curved part of the mold and the rear curved mold part are typically formed through injection molding techniques in which molten plastic is applied to highly machined steel tools with at least one optical quality surface.

The front and rear curve mold pieces are joined together to shape the lens according to desired lens parameters. The lens formulation was subsequently cured, for example, by exposure to heat and light, thereby forming a lens. After healing, the mold pieces are separated and the lens is removed from the mold pieces.

The molding of ophthalmic lenses has been particularly successful for high volume applications of a limited number of lens sizes and powers. However, the nature of injection molding processes and equipment make it difficult to form specific custom lenses for the eye of a particular patient or a particular application. Consequently, other techniques have been explored, such as: turning a lens button and stereo lithography techniques. However, turning requires a material for high modulus lenses, requires a lot of time and is limited to the scope of the available surface and stereo lithography has not yet produced a lens suitable for human use.

WO 2005/005121 A2 describes a method of manufacturing a mold to produce an optical surface, such as a custom contact lens. This is achieved by providing a mold surface with a photoresist layer and exposing the photoresist layer to a predetermined pattern of exposure radiation for a predetermined time and then subsequently developing the photoresist layer by selectively removing the photoresist material according to the radiation pattern and forming the exposed surface of the layer to the required final form of the mold.

US 2004/0222539 A1 discloses an apparatus for manufacturing a contact lens by crosslinking by means of impact on a UV radiation mold. The apparatus has a pump between the mold member and the container base through which the material can be transported away from the container through an outlet. The formed contact lens is removed from the apparatus by a grip device that uses negative pressure to suction the contact lens against a grip plate and then the grip device is turned back into the gap.

It is therefore desirable to have additional methods and apparatus that lead to the formation of an ophthalmic lens of a predetermined size and shape such that it can be customized for one or both of a specific patient or purpose.

SUMMARY OF THE INVENTION

The present invention is directed to an apparatus for forming an ophthalmic lens according to embodiment 1. In general, a reactive mixture is exposed to the source of actinic radiation through a substrate with an arcuate surface. At least a portion of the arcuate surface may include an optical quality surface. Actinic radiation is controllable to cure a portion of the reaction mixture in a predefined pattern. The predefined pattern may include a surface formed along the optical quality substrate surface and a second free surface formed within the volume of reactive mixture.

Several embodiments may include an apparatus for controlling actinic radiation, such as a homogenizer and a collimator. The actinic radiation source may include a spatial light modulator, such

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such as a digital device. In some embodiments, the substrate may include an ophthalmic lens mold part.

Additional embodiments include a substrate that supports a lens precursor and a fluid removal device close to the lens precursor, in which the fluid removal device is positioned to remove one or more of: partially reacted, reacted and reactive reaction mixture unreacted and gelled material. Other aspects may include environmental controls such as mechanisms to adjust one or more of: temperature, humidity, particulate, light and gas environment, during the formation of the Lens Precursor or a lens.

Embodiments include a source of actinic radiation fixation suitable for forming an ophthalmic lens from a lens precursor. Other aspects may include processors and software storage devices capable of controlling the automated apparatus discussed herein.

A first section of the apparatus provides the construct for taking the necessary optical parameters and converting them into a material product that in subsequent production will reach the desired ophthalmic lens parameters. This first section includes the Voxel-based lithographic optical device. By exposing programming intensity in a digital manner, and delivering exposure to discrete locations across the curved surfaces of an optical component, the apparatus. It causes an actinic reaction, which occurs in a controllable and programmable way.

One of the products that can result from processes using the Voxel lithographic optical section of this device is called a lens precursor. This lens precursor has both fluid and structural regions. In a preferred embodiment, the structural regions are largely. determined by the operation of the lithographic section of Voxel; however, the fluid region can be determined in numerous ways while also being influenced by the Voxel lithographic section. Alternative embodiments may form a lens of the effect of the Voxel lithographic section without passing through the intermediate product of the Precursor Lens.

The Lens Precursor can be further processed in a second subsection of the new apparatus useful for processing the fluidity component. This section of wick includes a useful apparatus for adjusting and controlling the quantity and other characteristics of the fluid component in the entity of the Precursor Lens.

An additional subsection of the apparatus includes components that allow the controlled transformation of this remaining fluid material under forces that affect its fluidity appearance. By controlling the flow, high quality unique surfaces can result after the fluid material is fixed in a second actinic irradiation process.

The lens yields of these various subsections are further processed into sections useful for lens measurement, both in a swollen and non-swollen form. In addition, the apparatus for lens hydration and inflammation still includes other subsections of the apparatus. The result is ophthalmic lenses that achieve optical and functional requirements.

Some embodiments are the result of an apparatus thus formed in its sections and assembly, which forms customizable ophthalmic lenses in a free form.

Other embodiments derive from the ability of an apparatus to form a Precursor lens in a flexible and programmable manner through Voxel-based lithographic processing.

The ability to process precursor lenses in various forms in high quality ophthalmic lenses; include other embodiments of said novel apparatus.

Further embodiments utilize the ability of the Voxel lithographic apparatus to form Ophthalmic Lens Precursors and lenses that have characteristics in addition to the optical characteristics of parts thereof.

The methods of using the apparatus are further described in the processing application entitled "Methods for the formation of an Ophthalmic Lens Precursor and Lenses" presented simultaneously with this.

Accordingly, the present invention includes an apparatus according to claim 1 to form a personalized contact lens, with varied optical performance and with varied non-optical characteristics in a flexible and programmable manner. An ophthalmic lens is produced comprising a material of varied nature; including a hydrogel lens, and, in some embodiments, a silicone hydrogel lens.

BRIEF DESCRIPTION OF THE DRAWINGS

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Fig. 1 illustrates steps of the method that can be used to implement some embodiments.

Fig. 2 further illustrates steps of the method that can be used to implement some embodiments.

Fig. 3 illustrates an example of the relationship between absorbance and transmittance with formation and fixed radiation.

Fig. 4 illustrates an example of a lens produced with the invention described herein.

Fig. 5 illustrates components of the apparatus that may be useful in the application of some embodiments of the present invention comprising Voxel-based lithography.

Fig. 6 illustrates exemplary light source apparatus components that may be useful in the application of some embodiments of the present invention.

Fig. 7 illustrates exemplary optical apparatus components that may be useful in the application of some embodiments of the present invention.

Fig. 8 illustrates components of the exemplary digital mirror apparatus that may be useful in the application of some embodiments of the present invention.

Fig. 9 illustrates additional components of the apparatus that may be useful in the application of some embodiments of the present invention.

Fig. 10 illustrates an exemplary formation optics that may be useful in the application of some embodiments of the present invention.

Fig. 11 illustrates an exemplary monomer pool that may be useful in the implementation of some embodiments of the present invention.

Fig. 12 illustrates an exemplary material removal apparatus that may be useful in the application of some embodiments of the present invention.

Fig. 13 illustrates the gross movement systems of an exemplary material removal apparatus that may be useful in the implementation of some embodiments of the present invention.

Fig. 14 illustrates an exemplary stabilization and fixing apparatus that may be useful in the application of some embodiments of the present invention.

Fig 15 illustrates an exemplary metrology system that may be useful in the application of some embodiments of the present invention.

Fig 16 illustrates an exemplary hydration and extraction system that may be useful in the application of some embodiments of the present invention.

Fig. 17 illustrates an example cross-sectional representation of a Lens Precursor.

Fig. 18 illustrates an exemplary cross-sectional representation of a combined lens forming optics and mixing reservoir of reactive monomers.

Fig. 19 illustrates an exemplary model production for thickness formed against exposure time at different exposure intensities.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides an apparatus according to claim 1 for forming a lens and for forming a lens precursor and an ophthalmic lens precursor. Detailed descriptions of embodiments of the invention will be provided in the following sections. The description of both preferred and alternative embodiments, although detailed are only exemplary embodiments, and it is understood that for those skilled in the art that variations, modifications and alterations may be apparent. It should be understood, therefore, that said embodiments do not limit the breadth of aspects of the underlying invention.

GLOSSARY

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In this description and in the claims directed to the presented invention, several terms can be used for which the following definitions will apply:

"Actinic radiation" as used herein refers to the radiation that is capable of initiating a reaction.

chemistry.

"Arcuato" as used here, refers to a curve like that of an arc.

The "Beer Law" referred to herein and sometimes referred to as "Beers-Lambert Law" is: I (x) / I0 = exp (-acx), where I (x) is the intensity as a function of the distance x of the irradiated surface, I0 is the intensity of incident on the surface, a is the absorption coefficient of the absorbent component, and c is the concentration of the absorbent component.

"Colimar" as used herein means the limitation of the radiation cone angle, such as the light that proceeds as the output of a radiation receiving apparatus as an input; In some embodiments, the angle of the cone may be limited such that the rays of light coming from are parallel. Therefore, a "collimator" includes an apparatus that performs this function and "collimated" describes the effect of radiation.

"DMD", as used herein, a digital micromirror device is a bistable spatial light modulator consisting of a matrix of mobile micro mirrors functionally mounted on an SRAM CMOS. Each mirror is independently controlled by the loading of data in the memory cell under the mirror to direct the reflected light, spatially arranging a pixel of video data to a pixel on the screen. The data electrostatically controls the angle of inclination of the mirror in binary form, where the mirror states are either + X degrees (on) or -X degrees (off). For current devices, X can be either 10 degrees or 12 degrees (nominal). The light reflected by the lit mirrors is passed through a projection lens and on a screen. The light is reflected outside to create a dark field, and defines the level of the black floor of the image. The images are created by grayscale modulation between on and off at a rate fast enough to be integrated by the observer. The DMD (digital micromirror device) is sometimes DLP projection systems.

"DMD sequence" as used herein refers to a control protocol for a spatial light modulator and also for the control signals of any system component, such as, for example, a source light or filter wheel. any of which can include a series of scripts in time. The use of the acronym DMD is not intended to limit the use of this term to any particular type or size of spatial light modulator

"Fixation radiation" as used herein, refers to actinic radiation sufficient for one or more of: polymerization and crosslinking of essentially all of the reactive mixture comprising a Lens or Lens Precursor.

"Fluid Lens Reactive Media", as used herein means a reactive mixture that is capable of flowing either in its native form, its reacted form, or partially reacted form and is formed after further processing in a part of a ophthalmic lens

"Free form", as used herein, "freely formed" or "free form" refers to a surface that is formed by crosslinking a reactive mixture and is not formed in accordance with a plaster cast.

"Gel Point", as used herein, will refer to the point at which a gel or insoluble fraction was first observed. Gel point is the degree of conversion at which the polymerization liquid mixture becomes solid. The gel point can be determined using a soxhlet experiment: Polymer reaction was stopped at different time points and the resulting polymer was analyzed to determine the weight fraction of residual insoluble polymer. The data can be extrapolated to the point that the gel is not present. This point where the gel is not present is the gel point. The gel point can also be determined by analyzing the viscosity of the reaction mixture during the reaction. The viscosity can be measured using a parallel plate rheometer, with the reaction mixture between the plates; At least one plate must be transparent to radiation at the wavelength used for polymerization. The point at which the viscosity tends to infinity is the gel point. The gel point occurs at the same degree of conversion for a given polymer system and specified reaction conditions.

"Lens" as used herein "lens" refers to any ophthalmic device that resides in or over the eye. These devices may provide optical correction or may be cosmetic. For example, the term lens may refer to a contact lens, intraocular lens, overlay lens, eye insert, optical insert or other similar device through which vision is corrected or modified, or through which the physiology of the eye is

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Cosmetically enhanced (for example, the color of the iris) without impeding vision. In some embodiments, preferred lenses are soft contact lenses made of silicone elastomers or hydrogels, which include but are not limited to silicone hydrogels and fluorohydrogels.

"Lens Precursor" as used herein, means a composite object consisting of a Lens Precursor Form and a Fluid Lens Reactive Mixture in contact with the Lens Precursor Form. For example, in some embodiments of Fluid Lens Reactive Media it is formed in the course of the production of a Lens Precursor form within a volume of reactive mixture. Separation of the Lens Precursor Form and Fluid Lens Reactive Media adhered to the Reactive Mixture volume used to produce the lens precursor form can generate a Lens Precursor. In addition, a Lens Precursor can be converted into a different entity, either by removing significant amounts of Fluid Lens Reactive Mixture or converting a significant amount of Fluid Lens Reactive Media into non-fluid incorporated material.

"Lens Precursor Form" as used herein, means a non-fluid object with at least one optical quality surface, which is consistent with its incorporation into its subsequent transformation into an ophthalmic lens.

"Lens Formation Blend" as used herein, the term or "Reactive Blend" or "RMM" (monomer reactive blend) refers to a monomer or prepolymer material that can be cured and crosslinked or crosslinked to form a ophthalmic lens Various embodiments may include lens formation mixtures with one or more additives such as: UV blockers, dyes, photoinitiators or catalysts and other additives one might wish in ophthalmic lenses such as contact or intraocular lenses.

"Mold", as used herein, refers to a rigid or semi-rigid object that can be used to form lenses of uncured formulations. Some preferred molds include two mold parts that form a front curve mold part and a rear curve mold part.

"Radiation Absorption Components" as used herein, the term "refers to the radiation absorption component that can be combined in a monomer reactive mixture formulation and which can absorb radiation in a specific wavelength range. .

The Reactive Mixture (sometimes also referred to herein as: Lens Formation Mixture or Reactive Monomer Mixture and with the same meaning as "Lens Formation Mixture")

"Release of a mold" as used herein, "release of a mold," means that a lens either separates completely from the mold, or is only attached loosely so that it can be removed with gentle agitation. or pushed out with a swab.

"Stereolithographic Lens Precursor" as used herein, means a Lens Precursor, where the Lens Precursor Form has been formed through the use of a stereolithography technique.

"Substrate" A physical entity on which other entities are placed or formed.

"Lens Transient Reactive Media", as used herein means a reactive mixture that can be maintained in a fluid or non-fluid form in a Lens Precursor Form. However, Transient Lens Reactive Means are significantly removed by one or more of: cleaning, solubility and hydration measures before they are incorporated into an ophthalmic lens. Therefore, for clarity, the combination of a Lens Precursor Form and the Transient Lens Reactive Mixture does not constitute a Lens Precursor.

"Voxel" as used herein "Voxel" or "Actinic radiation voxel" is a volume element, representing a value on a regular grid in three-dimensional space. A voxel can be seen as a three-dimensional pixel, however, in which a pixel represents 2D image data a Voxel includes a third dimension. In addition, where voxels are frequently used in the visualization and analysis of medical and scientific data, in the present disclosure, a Voxel is used to define the limits of an amount of actinic radiation, reaching a particular volume of reactive mixture, thereby controlling the rate of crosslinking or polymerization of the specific volume of the reaction mixture. By way of example, voxels are considered in the present disclosure as existing in a single conformal layer to a 2D mold surface in which actinic radiation can be directed normal to the 2D surface and in a common axial dimension of each Voxel. By way of example, the specific volume of Reactive Mixture can be crosslinked or polymerized in accordance with 768 x768 Voxels.

"Voxel-based Lens Precursor", as used herein "Voxel-based Lens Precursor" is a Lens Precursor in which the lens precursor form has been formed through the use of a Voxel-based lithographic technique.

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"Xgel" as used herein, Xgel is the extent of the chemical conversion of a crosslinkable Reactive Mixture in which the gel fraction becomes greater than zero.

Apparatus

The apparatus described in this invention is generally presented in this document in five main sections, and the first discussion of embodiments of the apparatus will be organized into logical discussions at the subsection level. These subsections are the Voxel-based lithographic optics apparatus, the wick apparatus, the stabilization and fixing apparatus, the metrology apparatus and the hydration apparatus. However, the subsections also function as an assembly apparatus and this should be considered in light of the subsection embodiments.

Voxel-based lithographic optical device

The Voxel-based lithographic optical device is the component that uses actinic radiation to create lens forms and Lens Precursors. In the present invention, a very uniform intensity radiation-taking apparatus and irradiation controls on the surface of a formation optic at numerous discrete points on the optical formation surface, essentially on a Voxel by Voxel basis. This control allows this component to control the degree of reaction that occurs in the reaction mixture along the light path of a particular Voxel location; Ultimately determined the volume of material reacted there and, therefore, the form of Lens Precursor formed therein.

The main components of the Voxel-based lithographic optical apparatus are depicted in an exemplary embodiment in Fig. 5. Each indicated component is discussed in detail in a later section. At this point, an example overview is given for subsection functions.

Referring now to Fig. 5, the forming apparatus 500, in this exemplary operation can functionally start at the light source 520. In such embodiments, the light generated at this source 520 emerges as light in a band of wavelengths defined, but with some spatial variation in intensity and direction. Element 530, a spatial intensity controller or collimator, condenses, diffuses and, in some embodiments, collimates the light to create a beam of light 540, which is very uniform in intensity. In addition, in some embodiments, the beam 540 strikes a DMD 510 digital mirror device that divides the beam into intensity pixel elements, each of which can be assigned a digital on or off value. Actually, the mirror in each pixel simply reflects the light in one of two paths. The "ON" route, article 550, is the path that leads photons from media to a reactive chemical. On the contrary, in some embodiments, a "OFF" state includes a light that is reflected along a different path that will be between the paths represented as elements 516 and 517. This "OFF" route directs photons to influence a landfill 515 beam that has been carefully designed to absorb and trap photons directed towards it. With reference again to the "on" 550 route, light shown on this route actually includes the many possible different pixel values that have been set to the "on" value and are spatially directed along the individual path appropriate corresponding to its pixel position. An average intensity time of each of the pixel elements along their respective paths 550, can be represented as a spatial intensity profile 560, through the spatial network defined by the DMD 510. Alternatively, with an intensity constant that affects each mirror, article 560 can represent a spatial time exposure profile.

Continuing, each pixel element in the on state will see how photons are directed along its path 550. In some embodiments, the beam may be focused by a focusing element. By way of example, Fig. 5 500 represents an embodiment in which the light paths 550 are projected so that they affect in an essentially vertical manner on the optical surface of a formation optics 580. The image pick-up light proceeds now through the formation optics 580, and in a volume of space containing reactive lens mixture in a tank 590. It is the interaction of this light for a given pixel location, which defines a Voxel element in the on state in the volume in the tank 590, and around the forming optic 580. These photons in this volume can be absorbed and precipitate an actinic reaction in the molecule that absorbs it, which leads to a change in the polymerization state of the monomer in this general neighborhood

It is in this general way for a particular embodiment that Voxel-based lithographic optics can be understood to function. Each of these elements in its own right has features and embodiments that describe the functional modes of this apparatus. A greater understanding of the underlying invention can profite from a deepening of individual complexities.

Following now the basic understanding of the apparatus function presented above, the total system will be discussed as a whole. In some embodiments, Voxel-based lithographic systems as a whole are used to generate ophthalmic lenses. (A graphic representation of the wavefront surface of such a lens

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formed is illustrated in Fig. 4).

In some embodiments, an environmental environment, including temperature and humidity, comprising an apparatus 500 can be controlled. Other embodiments may include environments compatible with a laboratory environment and therefore may vary.

The nature of the environmental gaseous environment can be controlled, for example, by the use of nitrogen gas purge. Purging can be performed to increase or reduce partial oxygen pressure at predetermined levels. Humidity can also be maintained at relatively predetermined levels, such as at relatively lower levels than an office environment.

The level of vibration energy that is allowed to interact with individual device components is another environmental parameter that can be controlled in some embodiments. In some embodiments, large massive support structures define a relative low vibrational environment. Other embodiments may include some or all of the Voxel 500 lithographic system that relies on active vibratory supports. Without limiting the generality of possible solution, it is well known in the art that air bladder support pistons can significantly reduce the transfer of vibration in an isolated system. Other standard vibration isolation means can thus be consistent with the scope of the invention.

Particles in the environment of the apparatus may introduce undesirable defect modes of various types, including incorporation into product Lens Precursors and lenses. For example, in the optical path, the particles can modulate the actual intensity of one or more Voxel elements and / or affect the function of a particular mirror element. For these reasons, at a minimum, it is entirely within the scope of the invention to provide a control measure for particulate matter in the environment. An example of an embodiment to achieve this would be the incorporation of high efficiency particulate air filters (HEPA) into the body of the apparatus environment and a means to force the air through the filters sufficient to establish a laminar flow regime in exposed portions of the apparatus. However, any embodiment to significantly limit the levels of particles in and around the apparatus is within the intended scope of the invention.

Another aspect of the detailed environmental support for the optical apparatus according to the present invention includes ambient light and ways to control it. In some embodiments, ambient lighting provides actinic radiation and therefore it is prudent to limit parasitic sources of photonic energy.

Accordingly, in some embodiments, the apparatus 500 may be enclosed in opaque materials in line with the previously discussed environmental needs. A preferred embodiment may employ the use of filtered light sources in the environment of the apparatus, which may be sufficient to prevent exposure of active parts of the apparatus to contaminate the ambient lighting.

Referring now to Fig. 6, consider the light source as represented in a highlighted form 600. Specific aspects of light energy can be considered a fundamental aspect of any lithographic system and in embodiments of this invention using the Voxel-based lithographic optical apparatus, the nature of the light source for the system may be important.

In some embodiments it is desirable that a light source 620 provide the light in a narrow spectral band. The components of an exemplary lighting system 600 provide the means to achieve said narrow spectral character. In a preferred embodiment, a light source includes a light emitting diode 620, which exists in an environmental support and housing 610. By way of example, in some embodiments, a light emitting diode source 620 may include the light source AccuCure ULM-2-365 model with the light controller of Digital Light Lab Inc. (Knoxville, TN USA) This model emits a narrow band of light around 365 nm and also has the characteristics of a total width to maximum average width of about 9 nm. Therefore, this commercially available light source already emits light in a desirable narrow band without further apparatus. It may be clear that any LED or other light emitting product with similar characteristics can also be used.

Alternatively, wider spectrum light sources, such as, for example, carbon arc lamps or xenon lamps 620 can also be used. In this alternative, a broadband source 620 can be used. The light is emitted outside the ambient container 610 and proceeds through a wheel filter 630 deployed in the light source 620. The filter wheel 630, can contain several filters , different filters 631 in different operational places and these filters 631, can, for example, include a bandpass filter that will transmit the light centered at 365 nm with a total width at maximum half breath of a similar performance of 10 nm . In this embodiment, the filter wheel can be driven by a motorized actuator 610, which can index the filter wheel for different filters; and therefore allow the exemplary Voxel 500 lithographic system embodiment to operate at multiple selectable wavelengths.

It may be clear that numerous alternative embodiments can easily derive, including in

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a non-limiting perspective, the fact that the filter 631 can be mounted in a fixed manner in the vicinity of the broadband light source 620 and provide adequate routing. In another aspect, a multi-wavelength capability of such derived from an alternative embodiment in which there are multiple LED light sources 620, in the environment 610 that are individually activated for a different wavelength.

More generally, it should be apparent that some embodiments may include various light sources, including, for example, incandescent, laser, light emitting and other similar products with or without filters of various kinds. In addition, in some embodiments, light sources may be capable of emitting light in a controlled spectral band may be used and are within the scope of this invention.

The light source 600, moreover, can have the characteristic of being stable, uniform and relatively intense. In some preferred embodiments, an AccuCure LED 620 light source emits an intense light and includes an internal control feedback circuit to maintain a stable intensity for periods of time.

A light source 620 may include means to modulate the intensity in a controlled manner; including modulation of the on and off source with a defined duty cycle. Thus, for an integrated period of time, this intensity control mode will result in selectable average intensity levels of time. Alternatively, in a further operational embodiment, the LED source can modulate the intensity through a voltage-controlled mode of operation, where the change in intensity occurs for the independent time level of the emitted intensity.

For the stability of the output of any additional functions of light source component 620 in the environment of the light source may include additional embodiments. Examples of this aspect may include temperature control means through the cooling systems. Other environmental controls may include different definitions of embodiment consistent with the intent of this invention.

In a different aspect, the light source apparatus 600 offers an alternative embodiment for intensity modulation. The individual light source 620 can be operated to emit a given intensity and the filter wheel 630 can be operated by a motorized element 610, to intercept the light emitted with a neutral density filter 631. Therefore, the intensity of the Light provided to the rest of the Voxel 500 lithographic system will be modulated at a lower intensity. From a general perspective, it can be seen that the design of individual light filters 631 can imply numerous degrees of freedom and include different aspects of realization. By way of a non-limiting example, a filter can be designed to modulate the intensity in a spatially defined way such that a greater intensity is defined along a path through its body than in another path. In a second non-limiting example, a filter wheel can be designed to modulate the intensity in such a way that it is synchronized with the operation of the DMD, which allows the coordination of pixels and intensities defined by the density values of each segment. of the filter wheel. Combinations of these modes of operation provide alternative embodiments and it should also be clear that any means to control the light intensity of the features so described can be employed in the invention.

Regardless of the embodiment of the light source component 520, and its surroundings, an embodiment that includes a filter wheel 630, may allow an embodiment of an operating mode for the shutter in a filter element 631 that acts to completely block the irradiation of the rest of the optical system 500. There are numerous advantages for incorporating a function such as stability and longevity of optical components downstream. In addition, in some embodiments, the stability of a light source component 520 can be improved if it is allowed to operate continuously. A blocking filter 631, may allow the means of performing the steps in the rest of the operating system that require the absence of light from the light source 600. It may be apparent to one skilled in the art that while a place in Particularly of the filter wheel 630 has been described, there may be different appropriate locations along the optical path that include acceptable embodiments within the scope of the invention.

An additional component of a Voxel-based lithography optical apparatus includes a homogenization and collimation optics. This apparatus is designed to take the light output of the light source 520 and produces output radiation 540 that is of a more uniform intensity and focuses on the DMD 510. From a generalization perspective, it may be possible to achieve the purpose of the invention in the absence of these mechanisms, especially if the light source has components of similar intention.

The preferred embodiment is depicted in Fig. 7 700. As mentioned for the purpose of this section of the apparatus it is both to collimate the light coming from the light source and also to homogenize the light in relation to intensity. It turns out that in the preferred embodiment, the AccuCure 365nm LED 620 light source has provided optical components for collimating its light output. In a more generalized embodiment, such collimation apparatus would include the first component of this collimation and homogenization component. In the preferred embodiment, however, the light is sufficiently collimated by the light source 620 proceeds at 700 and strikes a set of approximately 1 inch focusing optics 710. These optics are included in

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commercially available lens components, for example, from CVI Laser, Inc. (Albuquerque, NM USA)

These two lenses 710 focus the source light on the light tube 720. This component 720 has the central role of homogenizing the input light, softening the lack of uniformity in spatial intensity. The light tube 720 includes a hexagonal shaped optical tube made of UV grade acrylic material. Although specific details of the embodiment have been described, it should be apparent that any alternative embodiment that provides an optical apparatus for homogenizing the spatial uniformity of source light includes solutions provided within the scope of the invention.

The homogenized light output of the light tube 720, is focused by a commercially available optical element 730 again of the type available from CVI Laser Inc. (Albuquerque, NM USA) for example. The focused light now proceeds through an aperture stop 740, to a set of focus elements 750 of approximately 2 inches. Again, these focus elements are standard, commercially available grade optics that are available through Thorlabs Inc. (Newton NJ. USA), by way of example. The intention, of focus optics 750, is now to direct the light to a specific point in the digital mirror device (DMD) 510. This completes the light path in the lighting section of the Voxel-based lithographic system. There may be numerous embodiments that can alter aspects of the collimator and homogenizer components to achieve the same objective in DMD 510 illumination with intense and uniform light of a desired central and spectral wavelength, which is within the scope of the invention. .

In the preferred embodiment, the lighting system articles 520 and 530 impart light (identified as 820 in Fig. 8 800) in and around the active elements comprising Texas Instruments of Digital Mirror Device 510. The DMD used in The preferred embodiment was obtained with a DMD Developer Kit: DMD Discovery 3000 available from DLi (Digital Light Innovations, Austin Texas, USA). The kit contains a DLi DMD Discovery 3000 A board with a Texas Instruments DLPtm XGA DMD chip (mirrors 768 x 1024) diagonal 0.7 "with UV transmission window option. A light processing board is also included. High speed ALP-3 linked to the D3000 board to act as a link for a D3000 device. Together, these components include 810 in Fig. 8 800 of the imaging system components of this preferred embodiment of the lithographic system a Voxel base A detailed description of the DLPTM XGA DMD TI can be obtained from TI as the Starter Kit Technical Reference Manual (DDC3000) for the DMD Discovery ™ 3000 Digital Controller.

The DMD 810 device can work to provide spatial modulation of the intensity of light exiting the lighting system. The Texas Instruments DMD performs this function digitally by reflecting the light of the micromirror components that form a single addressable location in the spatial network of the active zone of the device. Therefore, the intensity of the light that is reflected from the DMD 810 and through the imaging system 800, per se, is not changed, however, by controlling the duty cycle of the mirrors in a state or in an off state. , the average time intensity that is reflected from a single pixel location can be modified.

In other embodiments, a spatial light modulator (SLM) such as those available from Fraunhofer Institut Photonische Microsysteme of Germany can be used to control radiation on a Voxel by Voxel base and may include spatial modulation as a function of intensity 810. The mirror-like surface of the SLM can actually be composed of multiple (i.e., thousands) small movable mirrors, each mirror with its own storage cell within the integrated circuit. As the desired intensity profile image is sent to the SLM, individual mirrors either flex or remain flat (as opposed to the DMD TI that rotates or tilts the micro mirrors). The light reflected by the flexed mirrors is dispersed in such a way that it does not pass through or expose the actinic reactive chemical mixture.

Referring now to Fig. 8, as mentioned above, the active imaging element DMD 810 processes the light in a digital manner, reflecting it in one of two directions. In the off state, the path of light reflection is intended to never see the location with the actinic reactive chemical mixture. To ensure that the light directed in the direction of never seeing this path, part of an image system 800 may include a light dump 830. This landfill is included with highly absorbent surfaces that significantly absorb any light that falls on them and they are only reflected in deeper depths of the landfill itself. In the preferred embodiment, as a non-limiting example, these surfaces include ND absorption glass sheets such as those obtainable from Hoya Inc. (Tokyo, Japan).

The light that is reflected from mirror elements in the "on" position takes a different path and is directed towards the focus elements 840. As with the other optics of these approximately 1 inch focus lenses are standard components that they may be available, for example, from Thorlabs Inc. (Newton NJ USA). These 840 focusing lenses center the "on" status light that is emitted from the DMD 810 as an object in the formation optics where the light reaction occurs with the monomer reactive mixture.

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In some embodiments, it is desirable to provide a means of imaging and control of the state of the optical path directly, rather than inferring the results in produced lenses. In the preferred embodiment of the Voxel-based lithographic optical apparatus, the proportion is provided for this direct monitoring. Light that focuses on the formation optics 580, is intercepted with a mirror 850, which can be changed in and out of the beam path. The light directed in this way then strikes a detective photographic imaging apparatus 860.

Continuing now to Fig. 9, the components of the forming apparatus 900, affect the beam in the objective area of the reaction mixture. As mentioned above, in some embodiments, this light has focused on a normal orientation with the surface of the forming optic 930. In the illustrated embodiment 900, the light can affect the surface more or less vertically. of the formation optics 930. In alternative embodiments, a lens can be held in place by means of a retaining ring or other clamping device, shown as 921, which can maintain the correct orientation of said lens with respect to formation optics 930. From a broad perspective it should be noted that the invention includes numerous embodiments related to the path that light will take to a Voxel base by Voxel through the optical surface 930.

Continuing with Fig. 9, since the relative orientation of the reservoir and light beam formation optics is of importance, the mechanism for its interlocking location can be defined in some embodiments as demonstrated by the interaction of elements of a member of formation optics retention 970, and the reservoir to contain the monomer reactive mixture 950. The alignment between these two members will also provide for positive control of the centering of the reservoir 950 to the formation optics surface 930. Position control also it can be improved in some embodiments with the spacer ring function 951. This spacing will also control the volume of the monomer reactive mixture that can be added to the reservoir 950.

Fig. 9 also shows an aspect of the additional embodiment related to the control of ambient gases in the area of the monomer reactive mixture. Since in some embodiments, the presence of oxygen can modify the photochemistry of the monomers and act as a free radical scavenger, in some embodiments it has to be excluded from the gas surrounding the reservoir 950. This is achieved in the Fig. 9 900 through the containment vessel 990. By the flow of an inert gas, such as nitrogen, through 960, oxygen can be excluded from the environment. In yet another embodiment, the oxygen level can be maintained at a level by controlling its dilution in the gas 960, flowing through the containment vessel 990. Standard means, through the use of gas mass flow controllers for achieving a constant dilution level of oxygen in gas 960 are well known in the art and include embodiments within the invention.

Tank 950, which contains the reactive mixture, can be filled with an appropriate volume of said Reactive Mixture. In some embodiments, this filling could be performed before the formation optics 930, it is positioned with respect to the reservoir 950. In other embodiments, the formation optics 930 and the reservoir 950, can be placed inside a containment container 990 and can be it is purged with a flow of gas 960. The filtrate of the Reactive Mixture before use can also be used. From then on, a volume of the Reactive Mix 945 can be quantitatively introduced into the tank 950.

There may be numerous means for transferring Reactive Mix 945, including hand filling, quantitative liquid transfer by automatic means or filling until a level detector measures the appropriate level of Reactive Mix 945 in tank 950. From a general perspective, you can It is obvious to one skilled in the art that numerous embodiments for the transfer of an appropriate amount of Reactive Mix 945 may be practical, and such techniques are well within the scope of the invention.

In embodiments where the level of oxygen is essential for photographic processing steps, it may be evident that oxygen may be present as a species dissolved in the 945 monomer reactive mixture. In such an embodiment, means are required to establish the concentration of oxygen in the monomer 945 reactive mixture. Some embodiments for carrying out this anointing include allowing the mixture to inhabit the gaseous environment through which the purge gas 960 is flowing. Alternative embodiments may include vacuum purging of dissolved gases in a supply of the monomer mixture and reconstitution of a desired amount of oxygen during a dispensing of the mixture through the exchange of membrane gas with the liquid to be dispensed. Within the scope of the invention, it should be apparent that any means to establish the necessary dissolved gas at an appropriate concentration is acceptable. In addition, in a more general sense, other materials may act as appropriate inhibitors in the presence or absence of dissolved oxygen. From a more general perspective, embodiments that include an apparatus for establishing and maintaining an adequate level of inhibitor are envisioned within the scope of the invention.

Referring now again to Fig. 10, an exemplary form of a formation optics is illustrated, and its

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clamping and positioning apparatus 1000. The structure that holds the formation optics can include flat glass disc 1040. The formation optics can be located and fixed by means of an optically coherent adhesive 1020 using a mounting template to ensure alignment between The disk and the optics training. The flat surface of the disc provides positive orientation in the vertical direction, while a positioning notch 1030 and other flat surfaces not illustrated can allow radial and horizontal position control.

Referring now to Fig. 11, the disk 1000 is linked to the reservoir system 1100. The flat surfaces sit on three contact surfaces 1130. Some embodiments may additionally include a spring position pin 1120, which is loaded positively and article 1030 is placed. Two static position pins (not illustrated) involve two other flat surfaces in the optical formation assembly and the combination acts to kinematically locate the formation optics assembly, in all degrees of freedom, This guarantees repeatable and stable means of locating the formation optics in the light path. In some embodiments, a containment reservoir of reactive monomer 1110 may also be included. From a more general perspective, there are numerous embodiments, in accordance with the technique described in this document, which may be obvious to one skilled in the art of ways of centering a training optic, to locate such an optic in the proximity of a reservoir that will contain Reactive Mix to locate one or more such functions in a controlled environment environment.

Formation optics 1010 is at least partially transmissive to a desired spectrum of actinic radiation. Accordingly, various embodiments, formation optics 1010, may include, by way of example, one or more of quartz, plastic, glass, or other wavelength transmitting material for operating light to cure a used RMM. It can also be seen that the shape of the formation optics 1010 includes one of the surfaces 1011 with characteristics to be imparted in a lens or Lens Precursor, formed along the surface 1011 through polymerization resulting from the actinic radiation of formation passing through the formation optics 1010. Numerous embodiments of the form may include the technique of the invention herein.

Within the various embodiments that can be used for the design and characteristics of a training optics 1010, individual examples of said parts may have unique aspects related, for example, to their starting material, manufacturing, usage history and / or other causes. These aspects may or may not interact with the general function of the Voxel 500 lithographic system, creating unique optical offsets, for the Voxel intensity profile per Voxel necessary to ensure the achievement of a final product objective. Therefore, some embodiments may employ means to condition the formation optics 1010, maintain them and track them. By way of example, one embodiment may be to encode an identification signal in machine-readable format on: the flat surface of an optical part forming 1040. Additional embodiments could include, for example, the fixation of an identification device for radio frequency together with said identification mark of the mechanical reading. There may be numerous other embodiments for identifying individual optical forming pieces 1040, which may include the intent of this invention.

The output product of the Voxel 500 lithographic optical equipment may include numerous embodiments. In one embodiment, as shown in 900 a product reagent 940 is formed on the surface of the formation optics 930 while residing in the residual chemical reagent mixture 945. The action of eliminating the formation optics 930 with the reagent product 940, of the chemical mixture 945 may include additional embodiments of the apparatus. In some such embodiments, the formation optics 930 and adhered reagent product 940 can be raised outside the chemical mixture 945 under the action of robotic automation, for example.

In some embodiments, a manufacturing article that results from the process discussed may be an entity called a Lens Precursor. The Lens Precursor can adhere to the formation optics at the time of formation. A schematic representation 1700 is presented of what can be included in a precursor without the substrate or formation optics from which the Lens Precursor can adhere. This approximate representation illustrates, however, the key features of a Lens Precursor. The reactive product has a solid component, which is referred to as a Lens Precursor form, now identified as 1740. In this embodiment, the attached face (without forming the illustrated optics) is represented with an optical surface such as 1750. The Shape of Lens Precursor 1740 will now have a surface 1730 that has been defined by the operation of the Voxel 500 based lithographic system. Adhered to this surface 1730, it is a 1745 Fluid Lens Reactive Mixture. In such embodiments, means 1745 will remain in formation optics, where they may be exposed to further processing as described herein.

Material removal device capable of flowing

The 1700 Lens Precursor, which in some embodiments has been produced by a Voxel 500 lithographic optical system described above, defines a novel entity. A material extraction apparatus capable of flowing (sometimes known as a capillary apparatus) is a set of apparatus that can

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act on a 1700 Lens Precursor, and is described in detail below.

Referring now to Fig. 12 1200, a schematic representation of some aspects of an embodiment of a chemical elimination apparatus capable of flowing is demonstrated. The Lens Precursor is now shown attached to a 580 formation optic, and an alignment plate 1260 attached thereto. The combination is demonstrated as an embodiment in which the surface of the Lens Precursor is placed down. The 1745 Fluid Lens Reactive Blend will move under a variety of forces that includes gravity. A wick capillary 1210 is located in the vicinity of the 1745 Fluid Lens Reactive Mixture, around and in the fluid chemical that has been grouped at a low point along the lens surface. In a preferred embodiment, the hair wick may include a polymer wick effect model from a Safecrit, HP8U Model Untreated Plastic Microhematocrit tube. As an alternative example, the capillary can also include glass, metal or other material compatible with the physical and chemical / material requirements of fluid chemical removal.

Fluid chemistry 1740, is drawn on capillary 1210, and forms a volume 1241 that is extracted from the Lens Precursor. In one embodiment, the process can be repeated a number of times. After processing, the 1200 Lens Precursor is maintained with a reduced amount of Fluid Lens Reactive Mixture adhered to the 1750 Lens Precursor Form.

Various aspects of the Fluid Lens Reactive Mixture may be affected by this processing; including, for example, less viscous components in the Fluid Lens Reactive Mixture can be separated and removed. It should be apparent to those skilled in the art that there are many different embodiments related to how the chemical removal process can be carried out, all in accordance with the scope of this invention.

In general, the embodiment options may include numerous physical designs to extract chemistry from the surface. An example of a different embodiment may be the actuation of a component of the vacuum system 1220 to aid in the extraction of Reactive Mixture from Fluid Lens 1745. By way of non-limiting example, another embodiment may be to include redundant copies of the capillary apparatus 1210, deployed with its points that mimic the shape of the optical formation surface 580. In addition, the removal of chemical can be done with a large surface material, such as a sponge, or nanoscale materials with large surface area, such as example. The reiteration of a concept described above, an alternative embodiment may include controlling the rate of removal of a Lens Precursor in a formation optics 580, of Reactive Mixture 945. The surface tension forces in this embodiment may include a form of chemical removal, similar to a wick capillary step; and results in the reduction of the amount of 1710 Fluid Lens Reactive Mixture remaining when the Lens Precursor is translated. From a general perspective, the numerous embodiments of apparatus that could perform the function of removing portions of the 1745 Fluid Lens Reactive Mixture include the technique within the scope of the invention.

The component of the vacuum system 1220, in the preferred embodiment, has an alternative function to that previously defined. In the processing of multiple Lens Precursors, the chemical elimination apparatus 1200 will carry out the chemical elimination numerous times. The vacuum system component 1220 can be used to clean and evacuate the capillary apparatus 1210. A different embodiment may include a cleaning solvent flowing through the capillary apparatus 1210, in conjunction with the vacuum system component 1220.

In general, embodiments 1200 depicted in Fig. 12 illustrate how a chemical disposal system could work, and focuses on detail and a close-up view, on the components involved. In comparison, Fig. 13 represents a more global view of some embodiments of an embodiment of chemical disposal system 1300 to aid in the description of both the equipment used in a preferred embodiment and some alterations. Fig. 13 1300 includes a capillary extraction component 1305 and a Lens Precursor mounted in a formation optics and the formation of the optical plate 1306 in a similar configuration and with the Lens Precursor pointing straight down.

Referring now again to Fig. 13, it may be apparent that the placement of the wick capillary 1306 may in alternative embodiments be in a position outside the center of the Formative Optical Lens Precursor 1305, center point. Article 1330 indicates a unique dimension, of an xy translation table, where the adjustment is used to compensate the capillary for central optical alignment of formation. As an example, the 1330 represents a form of manual vernier adjustment of preferred embodiment. However, it may be apparent to one skilled in the art that the adjustment can be made by automation comprising stepper motors for example; and more generally, several levels of increasing sophistication in automation equipment for the location of the XY translation table should be provided within this invention. From an even higher level of generalization, and to simplify the following discussion, it can be assumed that any movement capacity in the apparatus can have the same freedom of realization possibilities.

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Article 1320, a training optics holding apparatus, includes an apparatus for flexibly holding a training optics in a desired firm place. The optical training piece, as depicted in 1000 in the previous discussion, may employ location schemes similar to when it is in the Voxel 500 lithographic apparatus in this embodiment. The alternative embodiments may allow the transfer of the optical holding apparatus 1000 under automated means. It should be evident that numerous alternatives in manners, of holding the formation and blocking optics in an appropriate place in a fluid chemical removal apparatus include consistent aspects of the present invention.

The discussion so far has generally represented embodiments with the axis of the formation optics positioned such that it is perpendicular to a horizontal plane and in the direction of gravitational forces. Alternative embodiments may allow shaft rotation at an angle of this perpendicular orientation. Article 1350 includes adjustment means to alter the angle that the optical axis of formation makes with gravity. The fundamental effect of this change would be that the fluid matter 1710 in the Lens Precursor will tend to group in a place outside the center of the optical training center. In some embodiments there may be advantages for the production of fluid media in a place outside the center.

A series of articles indicated in Fig. 13 refer to the location in a vertical manner of capillary wick apparatus 1306 to the fluid media in the Lens Precursor. For example, 1340 may include a rough or approximate adjustment of this dimension, by moving the stage placed in the wick capillary 1306 along the vertical axis. In addition, 1345 includes a fine level adjustment for the same possibility of movement. It is equivalently possible to adjust the assembly phase forming optics 1310 in relation to the capillary wick effect apparatus 1306 along the same axis. Article 1370 includes a fine adjustment apparatus for this purpose.

For the purpose of moving the hair wick in different orientations 1360 includes a rotary movement device. For example, such an embodiment may allow simplified and automated capacity to change the wick device 1306.

As mentioned, there may be numerous embodiments that relate to the automation of movements between the various components of the fluid chemical removal apparatus 1300. In addition, however, it is entirely within the scope of the invention for alternative embodiments to include optical measurements to control the chemical elimination process. Additional alternative embodiments for such monitoring may include, for example, liquid level sensors of various types. By way of generalization, it may be obvious to one skilled in the art that the process of partially controlled removal of a fluid chemical mixture from a solid support may require numerous detection and metrology devices.

Embodiments related to the apparatus for reactive chemical removal of fluent lens include methods and apparatus for the removal of a portion of chemistry 1710 from the surface of the Lens Precursor Form 1730. It may be apparent to one skilled in the art, that The chemical cleaning steps may include embodiments with more aggressive cleaning options. Through the use of industry standard cleaning techniques, the 1710 fluid lens reactive chemistry can be partially or almost completely removed. By definition, the apparatus with such a cleaning action would be to convert the 1700 Lens Precursor into a different form. However, in some embodiments, it may be possible to reconstitute a Lens Precursor after said lens cleaning technique by applying a Reactive Mixture back to the surface of Lens Precursor Form 1730, such as, for example through of deposition, spraying, inkjet or wick effect.

Other embodiments of the chemical removal cannot use external equipment to a 1740 Lens Precursor form. On the other hand, since the 1740 Lens Precursor Form may be defined by numerous embodiments, there are designs of a Lens Precursor Form. which may include depressions or topographic channels (Article 440 of Fig. 4400 includes some examples of realization of such characteristics and is discussed in other sections of this document) in certain places of the Lens Precursor Form 1740. When guiding the Reactive Mixture of Fluid Lens 1710 in the channels of a reduction in the amount of the Fluid Lens 1710 Reactive Mixture "on", the Lens Precursor Form 1740 can be obtained and include such an alternative embodiment of chemical removal. In general, it may be obvious that in embodiments of this type, the actual shape of topographic relief features to function in this way can vary and be generated on a free-form surface.

Stabilization and Fixation Apparatus

The 1700 Lens Precursor includes a base for additional embodiments of the apparatus for the custom formation of an ophthalmic lens. The fluidity layer of the Lens Precursor, shown in the representation of an embodiment as layer 1710 provides new ways to form an ophthalmic lens surface of optical quality. When a Lens Precursor stands, fluid media can move through time. Under certain conditions, for example, the period of time the fluid layer may extend under the forces of gravity and the surface to reach a stable entity. The surface

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of Stabilized Fluid Lens Reactive Blend 1710, may be represented by 1720. In certain embodiments, a resulting surface 1720, may include an optically superior surface compared to surface 1730 of the Lens Precursor Form 1740. Numerous apparatus may provide the functional capacity to stabilize the 1710 Fluid Lens Reactive Mixture.

Proceeding now to Fig. 14, a stabilization apparatus 1400 in a preferred embodiment is shown. One aspect allows the flow system to be isolated from movements or vibratory energy. This is achieved in 1400 with component 1450. A relatively massive table 1450 can be supported in a vibration isolation system 1440. As the force of gravity is also employed in such embodiments, it may be preferred for the massive table 1450 to have a flat surface that is level. A Lens Precursor 1410 can be attached to an optical forming support 1430 that can be attached to a clamping device 1451. In some embodiments, automated timing equipment can be used to control a minimum amount of time for fluid media to achieve a relatively stable state.

In some embodiments, the apparatus used for stabilization includes attached components that allow exposure of the lens Precursor to an actinic irradiation stage for the purpose of fixing the 1700 Lens Precursor in an ophthalmic lens formed. In some embodiments, the fixation radiation causes photochemical reactions that occur only in the 1710 Fluid Lens Reactive Mixture. In alternative embodiments, other parts of a Lens Precursor, such as, for example, a 1740 Lens Precursor Form, may go through one or more chemical changes under the fixation radiation. Other embodiments that constitute variations depending on the nature of the materials comprising the Lens Precursor may be obvious to an expert. In 1400, the source of fixation radiation is identified as 1460. As an example, a light source similar to that discussed above in the context of Voxel - the lithographic optical system 520 can be employed. For example, in some embodiments, An AccuCure ULM-2-420 light source with the Digital Lab Inc. (Knoxville, TN USA) 1460 light regulator may constitute an acceptable source of 1461 fixation radiation. After the appropriate parameters are carried carried out for stabilization, the light source fixing controller 1460 is switched to a position in the exposure of Lens Precursor and its surroundings to the fixation radiation 1461, and the formation of an ophthalmic lens of one embodiment . From a general perspective, there may be numerous embodiments relating to stabilization or otherwise moving the Fluid Lens Reactive Mixture across the surface of the Lens Precursor Form 1730 and then somehow irradiation with fixation radiation.

By way of example, some alternative embodiments for processing in the fixing apparatus may include a Lens Precursor Form where the fluid material may have been washed in a washing system. This application can anticipate numerous embodiments of materials and shapes where the fixing apparatus can fix materials that do not require a previous flow of a fluid material on the surface to be fixed. As an example, a Lens Precursor Form that has been formed with the Voxel-based lithographic optical system and washed 1710 Fluid Lens Reactive Mixture can still include an embodiment where the fixing apparatus is capable of fixing the Lens precursor in a lens.

A set of embodiments includes alternative ways to cause the 1710 Fluid Lens Reactive Blend movement. By way of example, in some embodiments, stirring a Lens Precursor surface including 1710 Fluid Lens Reactive Blend may allow the Reactive Blend to move of Fluid Lens 1710. In addition, for example, it may be desirable in some embodiments to rotate a Lens Precursor around a central axis in a common centrifugal form to sheet processing.

Still other embodiments may include minimization of the gravitational force experienced by the 1710 Fluid Lens Reactive Mixture by dropping the 1410 Lens Precursor in a controlled manner over a certain distance. Additional embodiments may alter the effect of gravity, changing the level of the surface 1450 at which the Lens Precursor 1410, formation optics 1420, and fastener 1430, are allowed to rest. With a different surface level, the forces on the 1710 Fluid Lens Reactive Mixture in the central optical region may vary and cause movement.

In another aspect, some embodiments may include chemical or physical changes to the 1710 Fluid Lens Reactive Mixture. By way of example, an alternative embodiment may include the introduction of a solvent material into and around the fluid reactive chemistry in such a way to change Its fluid nature. In addition, said added material can effect the surface energy properties of the components in the Lens Precursor system 1700. The properties of fluid reactive chemistry 1710 can be partially altered through the use of fixation irradiation 1461, to alter the nature fluid in a way that is different from fixation. Numerous alternative embodiments of a general nature relating to the changing properties of the fluid chemical system can be anticipated by the nature of this invention.

At a significantly fundamental level, the nature of the reactive chemical mixture 945 can interact with the various embodiments of an apparatus to allow different results. It should be clear that the nature of the stabilization and fixation apparatus 1400 and variation in the embodiments that derive from

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Changing the fundamental chemistry components in the reactive chemical mixture include embodiments within the scope of the invention. By way of example, this could include, for example, changes in the wavelength used for fixation, radiation and can introduce embodiments of the apparatus that have flexibility in said wavelength of fixation radiation.

As the Lens Precursor materials may include part of a designed lens, it may be apparent to one skilled in the art that environmental controls in the stabilization and fixation apparatus include important aspects of performance. For example, the control of particulate matter with, for example, the flow of filtered air HEPA may include an embodiment of environmental control. As the fluid media remains sensitive to actinic radiation, controls of the parasitic light entering the environment include additional embodiments. In turn, moisture and other gaseous pollutants can affect the quality of the lens and control of these environmental conditions may include alternative embodiments. The numerous aspects of environmental control that may be apparent to one skilled in the art include the technique within the scope of this invention.

The treatment product of a Lens Precursor of some embodiment with the stabilization and fixation apparatus may include devices that are similar to or forms of ophthalmic lenses. In many ways this material has characteristics that are directly related to a final, hydrated ophthalmic lens. However, many embodiments after lens stabilization and fixation create an entity, even in the formation and support optics 1430, which in the non-hydrated form can be subject to various forms of metrology.

Metrology apparatus

Continuing with Fig. 15, a representation of an embodiment of a metrology apparatus capable of measuring the optical and material characteristics. It may be obvious that metrology may be possible with the two "dry" lenses, as would be the result after processing, to the fixing devices mentioned above 1400; and with hydrated lenses. This embodiment, however, focuses on the metrology of dry lenses that are desirably still attached to the formation optics. Referring to Fig. 15, the dry lens 1520, is still fixed to the forming optics 1530 and its suitable clamping components 1540. For example, this clamping component 1540 is fixed to a pair of mounts 1550 and 1560, which together allow to control the movement of rotation of the lens around a central axis.

In some embodiments, the interaction of laser light 1515, from a laser displacement sensor 1510 such as that manufactured by Keyence (Osaka, Japan) model LT-9030, with the surface of the lens sample 1520 occurs at the time in which the sample forming optics 1530 1520 and the clamp 1540 rotate axially. A 1570 rotary servomotor drives a kinematic stage of rotary bearing on which the sample assembly sits. For rotation stability, the center of mass of the lens sample assembly is fixed, in some embodiments, as close to the center point as possible. As the stage rotates, the laser displacement sensor 1510 measures the movement of multiple points along the axial rings of the lens surface 1520. After the stage rotates a full turn, the displacement sensor 1510 is move azimuthal. Each movement creates the circular profile again around the lens surface. The process in this embodiment is repeated until the entire lens surface has been profiled. By measuring a particular formation optics 1530 without the lens sample 1520, the surface location of the formation optics can be obtained in an equivalent spherical notation format. Subtracting this result from the result with the lens in the optical results in a thickness mapping of the lens product. Again, the unique identification of a training optics in an embodiment for the apparatus, through an attached RFID or through some other means, may include another embodiment of the apparatus.

In some embodiments of this type, a free vibration displacement of the surface of the sample 1520 in relation to the sensor 1510 may include a significant error in the displacement measurement obtained by the system. Therefore, vibration damping and isolation can be included. Accordingly, in some embodiments, a massive support table 1580 sitting on vibration isolation mounts 1590 can be used to minimize the effects of vibration. Some embodiments may be less sensitive to vibration noise than others; However, in general various methods of minimizing modes of vibration energy transfer in the environment around the various forms of detectors and the sample location apparatus includes embodiments within the scope of the invention.

Other embodiments may employ different measurement systems, in some cases, in addition to the first laser displacement sensor described, to extract characteristics of the lens. By way of non-limiting example, a Shack Hartmann wavefront sensor available from Thorlabs Inc (Newton, NJ, USA), can also be used in some embodiments to determine the thickness of the lens body formed.

From a general perspective, there may be significant diversity in metrology devices that are envisioned within the scope of this invention, including in part and, for example, techniques for characterizing the

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refractive index, radiation absorption; and density Aspects related to environmental controls can also be predictable, including, for example, particle detection. These various techniques can be found in the same environment and location as the exemplary 1500 metrology device, or in alternative embodiments they may include additional locations within or outside the generalized system environment.

Collection, storage and communication of the metrology and logistic data related to the samples and the particular components used in the production of particular samples include a principle of general embodiment of the invention. These various data may be useful in establishing feedback loops for the control of lens characteristics. In an exemplary and preferred embodiment, the output from the metrology apparatus based on laser displacement sensor 1500 for a lens sample 1520 is recorded and stored in the computer system. The individual forming optical part, in one embodiment 1530, may have had similar laser displacement metrology performed therein before being used in the production of said sample 1520. Through the use of the displacement data data calculation system. they can be processed in some way to generate a representation of the thickness of the lens sample thus produced.

Within the computing system in a desired model for the lens sample, useful in providing starting points of the starting parameter for the different components in the lens manufacturing system, it can be compared with the manipulation of the displacement data for sample 1520, and formation optics 1530. In some embodiments, several location points in a model can be mapped or correlated back to the individual components of the imaging system; In the preferred embodiment, a particular Voxel element in the Voxel-based lithographic optical system. By adjusting the parameters for that Voxel, an upcoming lens or Lens Precursor sample can be produced with adjusted performance compared to the previous sample. Within the numerous embodiments of metrology and the various algorithms and calculation apparatus, there should be clarity for one skilled in the art that many alternative embodiments of obtaining, processing, modeling, feedback, and data communication include elements within the scope. of this invention.

In some embodiments, the metrology data of a particular system with respect to the thickness of a lens sample produced 1520 can be improved by using alignment features designed in the profile of a Lens Precursor Form 1720. In the example of Fig. 4, 400, thickness metrology obtained in a manner similar to that described above was obtained. Other discussions of this 400 will be made elsewhere in this description; but for the use of the understanding of an alignment embodiment, the 440 can be considered. Article 440 may include a relatively deep profile recess in the surface of a lens sample 1520. The design of such a feature may be useful in guiding numerous processing steps in the apparatus. In one embodiment, the signal related to 400 can be extracted or recognized by an algorithm or manipulation of the metrological data. Such extraction of this type may be useful in locating the portions of the various apparatus that are close to or provide processing at a location relative to the alignment characteristic 440. It may be apparent to one skilled in the art that numerous different embodiments of Alignment includes the use of marking materials and profile feature designs among others are possible and include the technique within the scope of this invention.

The use of metrology data produced by a 1500 metrology system by some alternative embodiments may use this data for diagnostic and control purposes of the entire ophthalmic lens production system or its various devices. By way of non-limiting example, the storage of the aforementioned measurement of a training optics 1530 may result in a history of such measurements. Through alternative calculation and algorithmic processing, surface characteristics could be compared over time and changes in those characteristics, either abruptly or steadily, could be used to indicate a need for diagnostic intervention. Some kind. An example, within the many possible causes of this signal change, could include that a formation optic has received a surface scratch of some kind on its surface. In further embodiments, statistical-based process control algorithms could be used both to establish acceptable limits on metrological results obtained and to mark a valid measurement change in an automated sense. Still other additional embodiments may provide means for automation in the system to react to these marks in an automated medium. However, from a general perspective, the scope of the invention anticipates these and numerous other embodiments of the use of metrology data of, for example, a system 1500, to diagnose and control the overall system.

The embodiments for the metrology apparatus discussed so far may generally refer to metrology in a "dry" lens sample 1520 or its formation optics 1530. From a more general perspective, however, similar or additional embodiments of Metrology can derive from measuring the characteristics of other forms in the total system. By way of non-limiting example, the "dry" lens can, in some embodiments, continue processing and hydrate. The metrology in such a newly defined 1520 sample could include an example of the more general discussion of realization. An additional example could include performing the metrology in a sample of 1700 Lens Precursor. Therefore, in

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In a general sense, there are numerous embodiments that are provided within the scope of the invention to carry out the metrology in the various forms of material used in the processing or generation of a product in such an ophthalmic lens production system. .

Hydration and Removal Apparatus

Another subsection of the apparatus for the production of an ophthalmic lens includes the steps of removing a lens or Lens Precursor from its formation optics, cleaning and hydrating it. In some embodiments, these steps can be performed essentially simultaneously. Proceeding to Fig. 16 1600 an embodiment of the apparatus for carrying out these steps, which is referred to as a hydration apparatus for simplicity, is represented. The apparatus comprises a container for the containment of the hydration fluid 1610. A fluid bath 1620, in which a lens 1630 and the formation optical support 1640 are immersed and a thermal control unit 1650, to keep the bath at a constant temperature

In a preferred embodiment, fluid bath 1620 includes deionized water (DI) in which a surfactant has been added. There are numerous embodiments of this bath that are practiced in the art and are consistent with the scope of this. invention. In an alternative embodiment, the fluid bath 1620 includes a mixture of organic alcohol, sometimes in a mixture with deionized water and a surfactant. Therefore, some embodiments of the container 110 may include materials that are consistent with the containment of a volume of water or organic alcohols and also the transmission of thermal energy between a temperature control unit 1650 and the fluid bath 1620. From a General perspective, there may be numerous alternative embodiments comprising container materials, container designs and means for filling and emptying the containers that fall within the scope of hydration and cleaning of a lens and include embodiments of this technique of the invention.

In some embodiments, the bath temperature is high to accelerate the operation of hydration, cleaning and disposal. In one such embodiment, the temperature can be maintained by the presence of a hot plate with a 1650 internal detection apparatus. More advanced embodiments may include alternative ways to heat the fluid that includes the alternative irradiation and materials and apparatus. drivers. And, additional embodiments may include different ways to monitor bath temperature and control within a temperature zone. An even more advanced embodiment could include the ability to vary or program the temperature of the fluid bath over time. It may be obvious to one skilled in the art that numerous embodiments exist to control the bath's hydration temperature that include embodiments within the scope of this invention.

As the exposure of the lens 1630 and the formation optics 1640 to the fluid bath proceeds and the lens is hydrated, in some embodiments the lens body will enlarge and eventually detach from the formation optics 1640. Therefore some embodiments they may include means of grasping the separated lens for mounting in appropriate storage and packaging means. Other embodiments may include, locate and collect the lens separated from the fluid bath means 1620. Alternatively, embodiments may provide the ability to force said fluid bath means 1620 during a drainage process to isolate a lens from the fluid. From a general perspective, numerous ways of locating a lens and handling it in a storage medium include consistent embodiments within the scope of this invention.

However, as indicated above, a lens in a swollen shape may include optical characteristics that more closely match the lens performance when the lens is worn by a patient. Therefore, in some embodiments, one or more stages of metrology can be performed on the swollen lens. Such embodiments may include similar aspects of feedback, control and diagnosis as discussed with other metrology measures and still further embodiments may be apparent to an expert that derive from the enlargement of the lens in the hydration apparatus.

These subsections include the five main subsections in this invention of an apparatus for the formation of an Ophthalmic Lens Precursor in a preferred embodiment, each having its own embodiment to define the apparatus. However, it may be evident that, since each subsection of the apparatus may contain numerous alternative embodiments, even at a higher level there are alternatives that may exist that either have an organization different from the subsections or alternatively may have one or more subsections omitted

Methods

The methodology described in this disclosure can essentially include five major subsections, and therefore, the discussion of some embodiments of the methods will be organized into logical discussions at the subsection level. The subsections are the methodology related to the production of lithographic Lens Precursors based on Voxel, a more generalized methodology for the production of Lens Precursors, the diverse methodology for processing Lens Precursors, the subsequent processing of lenses and Lens Precursors , and the

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Metrology methodology and feedback between the different sections. It should be noted that the following steps and description of the methodology are exemplary and are not intended to limit the scope of the invention as presented or set forth in the appended claims.

There are embodiments of the methodology that include all subsections or a subset thereof, so, accordingly, the order and inclusion of one or more stages of the described method does not limit the invention. Referring to Fig. 1, subsectional blocks of methodology 100 are identified, and include: a lithographic methodology based on voxel 110; alternative training methodology 120; Lens Precursor processing methodology 130; post processing methodology 140; and the metrology and feedback methodology 150. In Fig. 1, two entities are identified in the oval features; they are the Precursor of Lens, article 160; and the ophthalmic lens as element 170. Arrows with a single flow may include the general direction that some embodiments may take, and arrows with two heads represent that some or all materials, data and information may flow from the various methodological sections to and of the section for the measurement of core and feedback.

Voxel based lithographic methodologies

The production methods of Lens Precursors. Voxel-based lithographic devices include numerous embodiments related to the numerous embodiments of the apparatus, as well as numerous methods for using these embodiments of the apparatus in the processing of the Lens Precursors. Referring to Fig. 1, article 110, the voxel-based lithography methods, there is an initial step shown as Table 115, which may include the initial step in the manufacture of a lens of this system. Desired lens parameters can be entered into an algorithmic calculation. In some embodiments these parameters may have been obtained by measuring optical aberrations on the optical surfaces of an ophthalmic patient. These measurements can be converted into the wavefront characteristics necessary for the lens. In other embodiments there may be theoretical features of the lens wavefront that can be entered into the algorithm to determine the lens production parameters. It may be obvious to one skilled in the art that there may be numerous embodiments of the method in relation to the initial stage of defining the desired output lens characteristics.

Continuing with article 115, an algorithm takes the input parameters mentioned above, and in some embodiments correlates the parameters to previously produced lenses. A series of "frames" can now be determined for the exposure or script "film" that will be communicated to the spatial light modulator. It may be evident that there may be a multitude of embodiments related to the methodology that defines the algorithmic treatment of the required parameters that are introduced into an algorithm.

Similarly, there may be numerous methodologies that can be used to convert an algorithmic production for a particular voxel element in the planned light reflection profile at a time, which would include the "DMD" script. As an example, the value of the total intensity desired by the algorithm can be delivered to a voxel location in the reaction mixture as a series of time steps in which the input intensity of the light illumination systems is reflected during all the time. The integrated intensity of these complete "on" steps can then be complemented by another time step, where a partial value is written to the mirror element and therefore the mirror has a "cycle" level of duty cycle less than On full, during the remaining time steps that will be exposed to the reaction mixture as a whole, this particular voxel element could then be kept "off" for the remaining duration. An alternative methodology may include, taking the average intensity value for the number of steps or "frames" that will be delivered and using this value to adjust the bulk of the frame values that are sent to the DMD. It may be apparent to one skilled in the art, that the generality of spatial light modulators discussed in the previous discussion of apparatus, also has methodological correlations that correlates with the intention of creating this intensity and time exposure control.

While the methods described above are given examples related to the fixed intensity modulation applied to the space lighting device through the action of the space lighting device, more advanced methodologies can be derived if the intensity of the light source is modulated either at the source or in the optical system with light filtration. Other embodiments may be derived from the combination of intensity control both in the components of the lighting system and in the spatial lighting modulator. Even more embodiments can be derived from the control of the illumination wavelength.

The "DMD" script formation method, which from a general sense should be considered as referring to the control signals to any spatial light modulator of any size and also to the control signals of any system component, such as for example, the light source, the filter wheel and the like, can, therefore, generally include the creation of a series of sequences of instructions programmed over time. It may be obvious to one skilled in the art, that there are numerous embodiments related to the method of creating a control signal program that encompass the many embodiments of the details of actinic radiation, of the details of the optical system employee and the details of the materials that

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It comprises the monomer reactive mixture.

You can realize that the details of the "DMD" script and the algorithms may be related to the results obtained after the transformation. The feedback of the critical parameters will be discussed later, and such detailed discussion in this way deferred. However, in terms of the method of creating a DMD script, as shown in box 115, the double headed arrows pointing to and from the voxel-based lithography methodology and the metrology feedback and methodology are It refers in part to a role in this exchange of information in the methods for creating a DMD script.

Another entry in the methodology of the formation of Lens Precursors is included by the different methods in the formulation and preparation of a reactive mixture for the system. In Fig. 1, article 111 is a box representation of the different methodologies included in the reaction mixture. It may be apparent to one skilled in the art that the embodiments of the apparatus discussed include a high degree of flexibility in terms of the type of makeup and the components within the reaction mixture and the abundance of embodiments of the reaction mixture, the Element includes the scope of the invention.

Without loss of generality, for example, chemical components as monomer units in the reaction mixture may include chemicals that are photoreactive to light in the ultraviolet spectrum, as described in some of the embodiments. However, these monomer molecules could also be chosen so that radiation in the visible spectrum is absorbed photoreactively. The components within the system can also be adapted for consistency to another part of the electromagnetic spectrum. Therefore, it can be understood that the methodology of the materials in relation to this invention may include molecules sensitive to actinic radiation across a large part of the electromagnetic spectrum.

In some embodiments, the monomer mixture is actually a mixture of one or more types of actinically reactive monomers that is also mixed with other chemical components. As a non-limiting example, other chemicals can be included as absorbent compounds. Such an additive to the monomer mixture may, for example, be important in embodiments that operate voxel-based lithography such that the intensity of actinic radiation along the path defined by a voxel element can be modeled. by the Beer-Lambert-Bouguer Law. This component can largely define the thickness sensitivity of the formation process within the voxel element. It may be obvious to one skilled in the art that an abundant amount of embodiments may include technique within the scope of this invention to add a component of the monomer mixture that absorbs light into a corresponding spectral region.

In other embodiments, the absorption component of the monomer mixture may include the additional complexity to which it has just been exposed. For example, it may be within the scope of this invention for a method of defining the absorber component to be included of multiple molecules that absorb light in different ways. Additional embodiments may derive from the absorption elements of compound compounds that have multiple and relevant absorption bands, themselves. Other additional embodiments of the methodology may include the addition of components to the mixture of monomers having a combined monomer and absorbent paper. This combined function may, in some embodiments, also allow a continuous absorbency role even after a monomer undergoes a chemical reaction. And, the opposite case may include embodiments of the method, where chemicals that have the altered absorption characteristic when actinic reactions occur are added. From a general perspective, it may be clear that many embodiments of the methodology comprise a reactive mixture of monomers with a component to absorb radiation in one or more relevant spectral bands may be within the scope of the invention.

Additional embodiments may result, if the addition of an inhibitor component is included in the method of preparing a mixture of monomers. In this sense, a compound inhibitor would have a role in the reaction with a chemical that has formed in the monomer reactive mixture. In some embodiments, the absorption of actinic radiation can generate one or more chemical species of free radicals. An inhibitor can act in reaction with free radical species, and therefore, terminate a route of polymerization of reactions. An effect of such an embodiment would be to limit the duration of a photochemical reaction polymerization, or otherwise limit the distance that a polymerization reaction may occur away from the original photoabsorption initiating event. It may be apparent that some embodiments of the addition of inhibitor to the monomer mixture, therefore, may have relevance to the spatial resolution that a collection of photons in a voxel element ultimately reflects in the spatial location of the reactions that start. In general, the action of the inhibitor may include numerous embodiments corresponding to the technique.

The types of chemical species or components of the reaction mixture that can act in an inhibitory manner also include many other embodiments of the technique. As with the absorber, which is inside

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of the scope of the invention for an inhibitor to perform a double function, in the inhibition of multiple polymerization pathways. In addition, the inhibitor may include a portion of a molecule of the monomer itself. And, in other forms of generality, the inhibitor may in turn have a thermal or photoreactive sensitivity. Still other embodiments may be derived from the nature of the inhibitor in its pure chemical state; since it can include a dissolved form in the mixture but exhibit gaseous, liquid or solid characteristics in its pure form.

The method of preparing a mixture of monomers may have additional embodiments with respect to the addition of an initiator component. The initiator can include a photoabsorbent component that in the absorption of a photon generates a chemical species that precipitates a polymerization reaction. The initiator may include a molecule that is significantly absorbed in a particular band. Other embodiments may occur with initiator molecules that are photoabsorbent in multiple bands relevant to the apparatus. Its absorption may include a relatively wide band of relevant frequencies as well. Even more additional embodiments are possible if the initiator component of the monomer mixture is derived from chemical initiator reactivity, one or more of the types of monomer molecules residing in the monomer mixture as well. It may be obvious to one skilled in the art that numerous alternative embodiments may include the methodology comprising a mixture of monomers with a component that acts as an initiator.

In some embodiments, the function of these described additives includes functionality towards the method for the formation of an ophthalmic lens. In an exemplary embodiment of the monomer mixture used was Etafilcon A, a reactive monomer mixture that has a general use in the production of ophthalmic lenses. Referring again to Fig. 3, Etafilcon A includes a monomer component that is formed from solids or gels under polymerization. Etafilcon A also includes an absorbing molecule, Norbloc, which absorbs UV radiation in a band that comprises the lowest wavelengths at point 300 and is represented for example as element 310. In addition, Etafilcon A also includes a component that acts as an initiator, and its absorbance is represented by item 340. In the mixture, the presence of dissolved gaseous oxygen includes an inhibitory role. Thus, the methodology for the formation of a monomer reactive mixture in this embodiment includes both the formulation of a mixture of solid and / or liquid components and also includes the control of a dissolved oxygen level. The description of this embodiment is exemplary, and, therefore, is not intended to limit the scope of the invention.

It may be apparent that other embodiments of the method for forming the monomer reactive mixture may be derived from the control of physical aspects of the monomer mixture. In some embodiments, this may involve the addition of solvents or diluents to alter the viscosity of the mixture. Other embodiments may be derived from other methods that result from the altered viscosity of the mixture.

In the methodology for the preparation of the monomer mixture, additional embodiments can be defined from treatments performed in the nascent mixture. By way of non-limiting example; The mixture can be subjected to an evacuated environment and it can cause desorption of certain dissolved gaseous species. In another embodiment, the monomer mixture can be treated by exposing the bulk mixture to exposure to actinic radiation, thereby altering the degree of distribution and population of multimeric components in the mixture before it is used in a post-actinic processing stage. It may be obvious to one skilled in the art that numerous additional embodiments may be possible for the purpose of treating a mixture of monomers to result in an altered characteristic; the resulting mixture being useful in the further purpose of producing ophthalmic Lens Precursors and lenses.

Moving along the arrow in Fig. 1, to box 112, the methods for dosing and deposition of the monomer reactive mixture are of relevance. In some embodiments, an amount of the reaction mixture may be equilibrated to have a desired concentration of dissolved oxygen. In some embodiments, equilibrium can be achieved by storing a container containing a significant amount of the monomer mixture in an enclosure where the environment includes the desired amount of oxygen that equilibrates at the desired concentration when dissolved. Additional embodiment may include automated equipment that can exchange the correct amount of oxygen in reactive mixture that flows through membrane technology. It may be obvious to one skilled in the art, that there may be numerous ways to alter the dose or the reaction mixture at a desired level of incorporating gas consistent with the scope of the invention.

In some embodiments, a volume of the dosed monomer reactive mixture can now be transferred in a manual medium into the reservoir comprising the container to contain the mixture in the vicinity of the optical forming surface. Other embodiments may include automated mechanisms to fill the reservoir with the monomer reactive mixture. Still other embodiments of the invention may include filling of disposable containers that can be used when necessary for the lens formation process. The scope of the invention includes the use of a methodology of some kind to fill the reservoir in the vicinity of the optical formation surface with at least an amount of monomer reactive mixture that is greater than the amount of material that a formed lens will include. After all the processing.

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It may be apparent to one skilled in the art that with the description of the various embodiments of the apparatus, embodiments of the monomer reactive mixture material, physical embodiments of the nature of actinic radiation, and embodiments of script control formalism and the apparatus that it includes, one can now describe some of the embodiments that will form the production of the lithographic methodology based on voxel. Moving in the process flow chart, Fig. 1, article 116 indicates the training methods that these various embodiments will use. It may be apparent to one skilled in the art that alternative embodiments for each of the components mentioned above may exist and that the description of the methods belonging to certain of said embodiments does not limit the scope of the invention herein.

It may be useful to consider part of the methodology of element 116 on a microscopic scale. Consider, as a non-limiting example, a general formation method in which a mixture of monomers includes an absorbent element such that there is a significant reduction in intensity absorption with the depth through which the photographed actinic radiation has passed ; as can be modeled in some realizations of the formalism of Beer's Law. And, for example, consider the embodiment represented in Fig. 3, where the wavelength of the actinic irradiation directed at a particular voxel element is such that it is in the region of wavelength actively absorbed for the initiator included in the reaction mixture and is in a rapidly changing absorption region for the absorber. Consider also, by way of non-limiting example that the monomer mixture includes an inhibitor. To facilitate the consultation and description, for this discussion this combination of methodology can be called Example 3. Although this is presented by way of allowing the embodiment, it is not intended to limit the scope of the invention and other models can be used.

In an embodiment of Example 3, the inhibitor can be found in a significant concentration in the monomer mixture. At the microscopic level, this exemplary embodiment could have the characteristic that incident actinic irradiation defines a very limited local region around itself where the chemical reaction initiated by actinic radiation in a particular element will occur at a rate that exceeds the capacity of the Highly concentrated inhibitor to inhibit compliance. Due to the fact that some spatial light modulator systems will have a portion of their surface between each individual modulation element as the "dead" space, it does not reflect the light in the same way as the modulation element, it may be evident that in this embodiment, the resulting material that is formed on the optical forming surface can take the form of the voxel-based columnar elements, which at the end cannot be connected to each other.

By way of continuous non-limiting examples of embodiments of Example 3, the inhibitor concentration can be found in a somewhat lower concentration and in this embodiment it can, for example, be in a concentration where the spatial propagation for a given set Actinic illumination parameters is just enough for each of the voxel elements to define actinic activity, which proceeds to occupy no boundaries between voxel elements. In such a case, on a microscopic basis, the individual columnar elements may tend to mix together for lighting conditions where neighboring voxels define significant intensity conditions. In some embodiments, the optical imaging system may be executed in a manner in which it is blurred as another embodiment of method for bringing the individual columnar elements to be mixed. In still other embodiments, a vibration or wobble movement of the optical formation lens and the support in space can lead to a similar effect in which the voxel elements overlap each other, forming a piece continuously.

It may be useful to continue describing the effects of the training methodology on a microscopic basis in the depth dimension of the voxel element. It may be evident, from the condition of Example 3, that "DMD script" of a particular voxel element can define the integrated intensity, or the exposure time that causes the reaction to occur at the voxel element depth of the optical surface deformation. At some particular exemplary depth, this condition may include a reaction condition of driven intensity in the monomer mixture in which the degree of reaction defines a gel point. At depths that are less than this depth, the reaction product may have formed a three-dimensional appearance; however, at depths greater than this depth, the reaction product may not have reached the gel point and may still include a mixture of components that is more viscous than the surrounding reactive mixture of incipient monomer due to a certain reaction level of monomer that has happened. In this embodiment, as may be clear, there was sufficient volume or the nascent reagent mixture to include at least these two regions; that is, the regions, where the reaction has occurred to a degree higher than the gel point, and the region where the material includes a non-gelled layer that may be a mixture of partially reacted monomers and mixture of unreacted monomers. In some embodiments, part of this layer may include what is called fluid lens reactive media. At the microscopic level, it is being formed within the volume space of the reaction mixture.

In other embodiments, the "DMD script" may be useful for defining the local design elements in the defined voxel layer that has reacted beyond the gel point. This entity can be considered a form of

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Lens Precursor in some embodiments. As a non-limiting example, consider the effect of incorporating an essentially linear feature in the DMD script that is a number of voxel elements in width, and many voxel elements in length and has the low intensity property integrated for all The voxel elements it includes. By using the embodiments described for Example 3, by way of non-limiting example, it can be envisioned that such linear characteristic is physically defined in the Lens Precursor Form. On a microscopic scale, neighboring voxel elements can include the intensity to define their thickness in the Lens Precursor Form at some significant level. In the first neighboring voxel element of the linear function, the shape thickness will be reduced, resulting in a characteristic related to the profile of the linear function defined in the DMD script.

By way of example, with reference to point 400 in Fig. 4, a representation of the thickness of a lens formed with a whole embodiment of this invention. In this example, the lens thickness shows some of the characteristics that have the characteristic of the linear characteristic, thus described. Article 440, for example, is a linear element that extends through many voxel elements through a lens. Although it may seem obvious, by deduction, that aspects of the invention include many different embodiments of shapes and characteristics of the profile that can be defined, in addition to the definitions of the optical surface of the lenses. Among the numerous possible embodiments, by way of example, there may be alignment characteristics, such as the intention of realization of feature 440. Additional embodiments may include profile features that define drainage channels, a linear function that is extends along an essentially radial path towards the edge of the Lens Precursor Form; wells or bottom holes in various shapes and sizes; steep steps up or down compared to the average neighboring topology; and essentially flat plateaus or features across a subset of the lens definition region. These examples are just some of the numerous embodiments that may be apparent to a person skilled in the art related to the training stage methodology.

Turning to step 117 of Fig. 1, in some embodiments the methodology related to the removal of the material, resulting from step 116, away from the environment of the monomer reactive mixture is described. In some embodiments, a method for this removal may include the process of lifting a formation optics with its clamp and with the Lens Precursor Form from the monomer reactive mixture reservoir. In other embodiments, the reservoir can be reduced away from the optics with the Lens Precursor Form attached. Still other additional embodiments can be derived from automation, either the step of lowering or raising with equipment capable of controlling the speed of said withdrawal with some precision. In alternative embodiments, the monomer reactive mixture reservoir can be drained resulting in some way in separating the formation optics with the attached Lens Precursor Form of the monomer reactive mixture. From a general perspective, it may be obvious to one skilled in the art that there are numerous embodiments that include step 117 of the removal of product from step 116 of the monomer reactive mixture; these embodiments that comprise the technique within the scope of this invention.

In Fig. 1, the products and intermediate products are indicated in the oval pattern. Therefore, Lens Precursor 160 in some embodiments includes a device entity. For the purpose of understanding other sections, with the discussion of the methodology, a review of the aspects of a Lens Precursor is warranted. The 1700 Lens Precursor may comprise two layers; 1740 Lens Precursor Form and fluid lens reactive media, article 1710. These layers, in some embodiments, correspond to the previous discussion of the training methodology. In some embodiments, the Lens Precursor form is the material that has been defined by the voxel-based lithographic system and has reacted beyond the gel point. It can have various structural embodiments discussed previously. In Fig. 17, the embodiment is portrayed where the voxel columns have been superimposed on each other during the training methodology.

The fluid lens reactive medium 1710 in some embodiments is the layer that is formed by the voxel-based lithographic process that is deeper than the point at which the gel point in the reactive media has been produced. When the formation optics and reacted material is removed from the monomer reactive mixture, it cannot be a viscous material that adheres to the surface of the Lens Precursor Form. In the present technical specification of the invention, this fluid sheet can, in some embodiments, be further processed with the methods to be described. This combination of a Lens Precursor Form and the fluid material therein that becomes after further processing of part of the lens is what constitutes a Lens Precursor. It may be evident that in some embodiments the lens precursor assumes a unique structure. That has a component that includes a three-dimensional shape, however, due to the fluid nature of the adsorbed reactive media, the entity does not have a fixed three-dimensional shape. It may be obvious to one skilled in the art that the scope of this invention includes all the various embodiments so that the training methods, article 116, include as well as the different embodiments related to the methods of eliminating the optics of training of the monomer reactive mixture and its effect on the nature of fluid lens reactive media.

In some embodiments, article 131, includes the implementation of the methodology to eliminate parts

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of the fluid lens reactive media of the Lens Precursor. As can be seen from the previous sections on the apparatus it comprises some embodiments to perform this methodology, there are a number of possible method embodiments for this purpose. By means of the non-limiting example, fluid lens reactive media can be removed by capillary action. In some embodiments, the methodology may include a step to allow some of the fluid lens reactive media to pool before the capillary action step is performed. In still other embodiments, the lens surface can be positioned so that its surface axis is angled with respect to the direction of gravity. It may be obvious that numerous embodiments relating to methods for removing fluid lens reactive media with a capillary-based apparatus may be possible and include the technique within the scope of this invention.

In other embodiments, the methodology for removing fluid lens reactive media may include an alternative apparatus for hair wick equipment. For example, a method comprising the use of an absorption surface to remove fluid media may include some embodiments. Additional embodiments may refer to methods that use apparatus with capillary points instead of the one described in detail. Even more embodiments may include methods for centrifuging the Lens Precursor to remove fluid material. Any of the numerous methods for using an apparatus to remove part of the fluid material, as may be obvious to one skilled in the art, may include aspects within the scope of this invention.

A different type of embodiment for removing the material from the upper surface of the Lens Precursor may include the method of defining the relief features in the lens body for this purpose. In this type of embodiments, features such as the drainage channels mentioned in a previous section can be designed in order to create a location to allow fluid media of relatively low viscosity to flow out, thereby creating grade space below for allow the relatively higher viscosity to flow inside. In further embodiments, the use of lens body rotation may also include embodiments for removing lens material in relation to the design of characteristic relief elements to allow the material to flow inside. It may be obvious to one skilled in the art that embodiments comprising the various embodiments of different relief surface design also include technique within the scope of this invention.

In some embodiments, it may be possible to avoid the removal of fluid lens reactive media and continue to additional processing steps. In Fig. 1, this aspect can be interpreted by the dotted arrow line that goes from the element 1160 around the box 131.

The next step shown in the embodiments that include the methods of forming an ophthalmic lens can be illustrated in Fig. 1 box is article 132, stabilization. In some embodiments, this novel methodology includes the processing method that allows fluid lens reactive media to flow under various forces to find a stable state, possibly of low energy, along the surface of the Lens Precursor Form. . At the microscopic level, it can be evident that a surface of a precursor form can have a certain level of roughness locally. Numerous aspects of the formation embodiments can determine the nature of this roughness, as an example of one such case, the effect of the inhibitor to relatively abruptly stop the reaction in the area that starts. The surface forces of the fluid media, friction and diffusion forces, the force of gravity and other applied forces are combined in many embodiments to create a smooth coating that has flowed through the topography. In the methodology that determines these forces there are numerous possibilities of realization within the scope of the invention.

In one embodiment, the Lens Precursor may be configured to allow fluid lens reactive media to flow under the force of gravity. The method to accomplish this could include the movement of the Lens Precursor in different orientations to aid in the flow. Alternative embodiments may include the opposite strategy by keeping the Lens Precursor in a fixed state with as little movement as practical. Even more alternative embodiments may include subjecting the fluid material to forces related to the rotation of the Lens Precursor about an axis. In some embodiments, this rotation may take place around an axis centered in the middle of the Lens Precursor. In alternative embodiments, said rotation may include the rotation of the Lens Precursor around an external axis point while the upper part of the Lens Precursor is positioned towards or from the axis point or in the innumerable possible orientations between them. In still other embodiments, the Lens Precursor can be processed in a free fall environment to minimize the effect of gravity. It may be apparent to a person skilled in the art that there may be numerous methods in relation to the application of fluid forces to the Lens Precursor during a stabilization method.

In other embodiments, the fluid nature of the fluid media can be altered by methodology. In some embodiments, the yiscosity of the fluid media can be altered by the dilution or solvation media. Alternative embodiments may include evaporation of part of the diluent to increase viscosity. Exposure to a certain level of actinic radiation may include additional methods to alter

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said viscosity of fluid sheets. There may be numerous embodiments related to the alteration of the viscosity of the fluid media.

In other embodiments, the forces related to surface energy in the fluid lens reactive media can be altered by the methodology. In some embodiments this may include the addition of surfactants to the incipient monomer reactive mixture. In alternative embodiments, additives or chemical reagents can be added to the Lens Precursor for the purpose of altering surface energy.

The design of the Lens Precursor Form may include methods for creating different flow conditions of fluid lens reactive media. Channels, as a non-limiting example, may include a means for extracting fluid lens reactive media from a Lens Precursor region. In alternative embodiments, design methods related to abrupt profile change may include methodology to provide altered stabilized states. For one skilled in the art, it may be apparent that there may be numerous methods in the design of Lens Precursor that include the technique within the scope of the invention.

From a general perspective, these various types of embodiments should not limit the generality of methods for creating a fully stabilized or partially stabilized or non-stabilized nature of fluid lens reactive media in the comprehensive stabilization of methodology. The combinations of the various embodiments, for example, may be obvious, to one skilled in the art, additional embodiments for said methodology.

After a stabilization methodology has been carried out, the fluid material can in some embodiments undergo a very successful type of methodology indicated as element 133, fixation, to convert it into a non-fluid state. In some embodiments, the nature of actinic radiation applied during the fixation method may include alternatives. The spectral band or bands applied can be an example of a type of methodology implementation. Alternative embodiments may include the intensity of the radiation applied. In alternative embodiments, the application of various aspects of fixation irradiation may include time dependence. By way of non-limiting example, an initial wavelength band may include a first step that is then changed to a different band. The universe of embodiments that may be obvious to one skilled in the art for the method of defining light conditions is within the scope of this invention.

In some embodiments of element 133, the method of fixation may include different paths that irradiation may take. In an exemplary embodiment, irradiation may occur on the front surface of the Lens Precursor; or, alternatively, through the back surface. Still other embodiments may be derived from multiple sources of irradiation, some perhaps with different light characteristics to create different effects, of actinic radiation in the Lens Precursor entities. Other additional embodiments may be derived from the method of fixation comprising other forms of energy than radiation. By way of generality, numerous methods that may include a fixing step are within the scope of the invention.

In some embodiments, after fixing has occurred, the processing of Lens Precursor 130 has been completed. This finished product may, in some embodiments, be subsequently processed. This type of products includes a good example of the type of technique indicated in block 120 of Fig. 1, alternative precursor formation. By way of non-limiting example, if the fixation product was reintroduced into the voxel-based lithographic methodology, a second processing layer can be produced. This aspect of multiple passes presents many methodological options for realization.

In some embodiments, the complex Lens Precursor that can be formed from multiple passes that may include by way of non-limiting example, a first stage in which an ophthalmic lens surface is defined and a second stage in which features of the surface profile are added. Other complex embodiments of the methodology may include, for example, a first pass through the voxel-based lithography system with conditions, such as some of the previous examples described, which make for voxel columns isolated along the Lens Precursor Form. A second step of voxel-based lithography can then include the filling of the characteristics between the voxel columns with a material of a different characteristic. Continuing a third pass through the system can then define an ophthalmic lens. It may be evident that the generalization to multi-pass methodology through the system, each of which may have the abundant different possibilities of embodiment discussed, may include a large number of different embodiments.

In some other embodiments, the Lens Precursor may be formed by the application of a fluid reactive medium on a Lens Precursor Form. For example, the Lens Precursor Formed through voxel-based lithography methods can be subjected to a washing system as an extreme method of extracting fluid lens reactive media. A Lens Precursor Form will be derived from the washing method. In some embodiments, this Lens Precursor Form may then undergo a method of adding

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reactive media of fluid lens to its surface. The methodology of adding the following fluid media to the surface, in some embodiments may include immersion and removal of the Lens Precursor in methods similar to the embodiments described in item 117. The resulting Lens Precursor may now have a distribution different from monomer and multimeric molecules, or in some embodiments may include polymer chemistry different from that used to form the Lens Precursor Form. It is perhaps evident to one skilled in the art that numerous embodiments comprising the methodology for applying fluid lens means in a variety of embodiments of Lens Precursor Form.

In an alternative set of embodiments, the Lens Precursor Form may be formed by means other than voxel-based lithography. In a first non-limiting example, various embodiments may be possible through the use of stereolithography as the basis for the formation of the Lens Precursor Form. In some embodiments, this Stereolithographically formed Lens Precursor Form may have fluid lens reactive media of an extraction methodology as in 117, but other embodiments may include the addition of fluid lens reactive media to the stereolithographically formed base. Alternative embodiments may be possible by using a masking lithography process for the determination of the Lens Precursor Form and then used in the aforementioned methods. Still other embodiments may include the use of a Lens Precursor Form that is formed by a common standard casting molding process in the manufacture of ophthalmic lenses, and then the formation of a Lens Precursor in the aforementioned methods. It may be apparent that the numerous embodiments that form a Lens Precursor Form may include methods to form a Lens Precursor.

After a Lens Precursor Form by one of the various embodiments of the method, and after processing by an embodiment of the method, it may in some embodiments form an ophthalmic lens as a result. In some embodiments, the lens will now still be on the surface of the formation optics. In most embodiments, it will have to be cleaned and hydrated to form an ophthalmic lens product form. In the methods that are generally standard in the art, the lens and in some embodiments of its attached form can be immersed in an aqueous solution bath. In some embodiments, this bath is heated to a temperature between 60 degrees and 95 degrees Celsius to aid in the immersion method. Such immersion methods will clean in some embodiments, the lens body and hydrate it. In the hydration process, the lens will swell and in some embodiments get rid of the support to which it is attached. It may be apparent that within the scope of the invention, it may be through coordination of the processing so that the same support and chemical handling structures may include embodiments for the hydration method as well. It should be noted that the above steps and description of the methodology are by way of example and are not intended to limit the scope of the invention.

The resulting product after release in many embodiments includes the ophthalmic lens formed of the invention. It may be obvious that other measures in this product are useful in the production of an ophthalmic lens of acceptable product. The methodology in some embodiments may include the standard technique for insulating the hydrated lens, packaging and then undergoing a sterilization process, article 142. It may be obvious to one skilled in the art that the order in which these steps include one with respect to the other and also relative to the previous steps may include different embodiments in accordance with the invention.

The various embodiments of ophthalmic lens, article 170, resulting from apparatus and methods described herein include another dimension of the technique in this invention. It may be apparent to one skilled in the art that the Lens Precursor product may manifest unique forms. First of all the lens on some level is a compound of two hardened layers. One of them, the Lens Precursor Form, is in some embodiments formed by the actions of the voxel-based lithography apparatus and methods. This Lens Precursor Form may have numerous embodiments, some examples of which may be apparent from the previous discussions of methodology.

For example, with some embodiments of methods, the form may include a set of relatively isolated columnar voxel elements each with a different extent determined by the voxel lithography process. In other embodiments, the Lens Precursor Form may include a completely interconnected set of columns of voxel-based material. It may be obvious to one skilled in the art, that there are numerous embodiments related to the actual composition of the monomer mixture. In addition, as mentioned earlier in the context of the methodology, the Lens Precursor Form may be formed by several other techniques than voxel-based lithography, including but not limited to stereolithography, masking lithography and mechanization. There are embodiments where the voxel-based lithographic form has profile features designed with the voxel-based technique; These include, but are not limited to linear functions, curvilinear characteristics, wells, partial height or full height characteristic, abrupt changes in topology, plateaus and channels.

Even more, the more complex embodiments can be derived from the multiple pass aspect of the invention. A Lens Precursor Form, by way of non-limiting example, may be the combination of a first pass to

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through a voxel-based lithography step that defines a spherical profile on the surface with abrupt features on its perimeter. A second step can define custom ophthalmic parameters in the active visible portion of the lens.

By way of generalization, it may be clear that there are embodiments comprising multiple passes through the apparatus and voxel-based lithographic methods. Variations may include different means to form the first pass, including alternative lithography options treated and, for example, a molded ophthalmic lens. This first type of material lens includes a Lens Precursor when acting in a second step, and can ultimately define a new embodiment of the lens.

The nature of the second component of a Lens Precursor, fluid lens reactive means, in some embodiments, when incorporated into the lens defines novelty in the realization of the lens. In case of transformation with the methodology and apparatus discussed by some embodiments, article 130, these embodiments may include a second distinguishable layer having a smooth surface. The combination of the numerous embodiments of the Lens Precursor Form and the various embodiments of fluid lens reactive media may include novel embodiments of an ophthalmic lens.

The formation of an ophthalmic lens can be improved through metrology and feedback 150. Some embodiments may include a flow of direct processing methodology of the box 116 through article 170; However, the higher embodiments may be derived from the use of metrology methods to conduct the parameter controls of the various methods employed. In Fig. 1, these feedback mechanisms and the flow of information by double headed arrows flowing to and from article 150 are schematically indicated. It may be apparent to those skilled in the art that numerous metrology embodiments may include the technique within the scope of this invention.

Proceeding to Fig. 2, an exemplary embodiment of a metrology and feedback loop methodology related to the thickness and optical performance of an embodiment of the lens formed by voxel-based lithographic methods is depicted. In some embodiments, it may be a feedback loop that functions as depicted in article 200, beginning with article 205 representing the input of desired lens parameters from an external source. By way of example, the lens surface model can be derived from an eye measurement device applied to a patient's eye. In other embodiments, theoretical input parameters may include the methodology of step 205. These inputs will be processed in some methodology to align with the input requirements of voxel 210 lithography. Various embodiments of the apparatus and method will receive this input. and, in some embodiments, with an algorithmic method convert them to usable parameters in the lithography system based on voxel 211.

Further proceeding in Fig. 2, a Lens Precursor is made in the voxel-based lithographic system as shown in item 220. Subsequently it can be processed with the Lens Precursor 230 processing methodology, resulting in a " seca "of an ophthalmic lens 240. This dry ophthalmic lens can now be measured in a metrology step 250. By way of example, this step may include the use of a laser displacement sensor. Again with the example, the surface topology result of this measurement may in some embodiments appear as shown in Fig. 4, article 400. Algorithms can process this data, as shown in articles 251 and 252. to compare the result to what would be expected if the lens corresponded to the input parameters of step 205. In some embodiments, the differences from the input parameters can be processed and correspond to a need to change the parameters used to process the lens in the 211 voxel-based lithography system. This data feedback loop and parametric information is represented in the feedback loop of article 253. The data can also be processed and correspond to changes in the desired parameters in the 252 Lens Precursor processing methodology. The evaluation of desired changes in the parameters of this 252 s system and represented by feedback loop 254. It may be apparent that the different calculation and control methodology can be made of different data processing equipment, including but not limited to central computers, personal computers, industrial computers and other similar computing environments. It should be noted that the steps shown in Fig. 2 and the description of the related methodology are exemplary and are not intended for the scope of the invention.

The results of the metrology stage 250, and the various processing of data 251 and 252, in

Some embodiments may include the ability to decide whether the lens produced 240 is within a set of acceptable limits around the input parameters of the element 205. A decision on this lens is shown below at point 251, where the objective can be discarded for another objective that

Produces with altered parameters. Alternatively, the lens may be within acceptable limits and, for

therefore, proceed to step 260 for processing in the post-processing methodology and realizations of devices. After the enlargement of the lens and its release it may be subjected to another metrology methodology as shown in item 270. In some embodiments, the result of this metrology could have similar feedback realizations as indicated in step 250 in this realization After a lens ophthalmic product 280 is made, the processing flow can be attached to the flow where the dry lens is

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rejection. Subsequently, it is possible for the entire flow to return back to step 205 in a step indicated by the condition return step 290. It may be apparent to one skilled in the art that there are numerous modifications, additions and alternatives in performing a step of metrology in the various products and then the development of a feedback loop that incorporates the measured results and adjusts the system parameters.

In some slightly different embodiments, an additional type of measurement can assess the aspects of lens quality for global equipment feedback. As a non-limiting example, a particle detection scheme can be deployed in some embodiments of measuring the presence of such defects in the Lens Precursor produced. If such a measurement resulted in marking a particle issue, it could be a feedback loop that could in some embodiments involve feedback to an operator of the apparatus and methodology to remedy the marked problem. It may be obvious to one skilled in the art that numerous metrology embodiments may include the technician where a measurement result is operator feedback.

In additional embodiments, the use of logistic information may include an element of a feedback loop. As mentioned in the discussions of the apparatus, in some embodiments, key components of the apparatus may have identification. This component identification can be tracked, in some cases, by an automation device. Feedback may include, for example, that a particular component has been used for a particular aspect that includes its useful life. Feedback can in some embodiments be made to an operator, or include automatic system responses. In still other embodiments that use component identification, the results of previous metrology embodiments, where thickness results affect system parameters, the unique identification of a component, such as optical part formation, may allow individual adaptation of otherwise global parameters to that particular component. It may be obvious to one skilled in the art that the disclosure described herein includes numerous embodiments in various ways to obtain logistics and metrological data, to process that data by various algorithmic means and by various data processing equipment. , to discriminate that the data from the input lens requirements and to provide means to feedback that data to the system itself or to operators outside the system; all of which are considered within the scope of this invention.

EXAMPLE 1

Various embodiments of the invention have been practiced and lens products and Lens Precursors in the ways described herein have been produced. In this section a discussion of the results of a set of embodiments is given as an example.

The apparatus for performing the results in this example comprises the following general aspects. A voxel-based lithographic optical device was used to form a Lens Precursor. This apparatus, from a general perspective, is composed of a light source of the preferred embodiment type operating at 365 nm. A homogenizer with an optical tube and optical focusing elements, as discussed, was used to illuminate the Texas Instruments DLPtm XGA Digital Mirror Device. The imaging system further comprises the imaging optics in a forming optics of the type depicted in Fig. 10.

The DMD pixel intensity and values profile is calculated based on the optical absorbance and reactivity of the monomer reactive mixture that is composed of Etafilcon A. This system has the absorbance characteristics as demonstrated in Fig. 3 with the peak irradiation 320, at 365 nm, and peak formation 330, at 420 nm. The absorbance characteristics of this system are consistent with the absorbance formalism of Beer's Law, and this was used to estimate the intensity program and the correct time for each of the more or less 768 x 1024 Voxel elements displayed in The whole face of training optics.

For purposes of illustration, the Beer-Lambert-Bouguer formalism is what was used to model the necessary intensity. The model results in a parametric dependence on the basis of this formalism and the variables related to the two materials, such as Etafilcon A, and the apparatus. The results of lens manufacturing passes are then fed again in such a way to refine the model parameters and generate a lens. The logic of the model follows.

Beer-Lambert-Bouguer Law:

Beer's law predicts that the intensity of actinic radiation will decrease exponentially in a material, depending on the extinction coefficient at (A).

I (x) / I0 = exp (-a (A) cx) Equation 1

The rate of intensity decrease with distance is

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dl / dx = -a (A) do exp (-a (A) cx) Equation 2

Where I (x) is the intensity as a function of the distance x from the irradiated surface, I0 is the incident of intensity on that surface, a (A) is the absorption coefficient of the absorption component as a wavelength function (A), and c is the concentration of the absorbent component in an otherwise relatively transparent medium. Therefore, by selecting the wavelength of the radiation, the process can be adjusted to select the intensity gradient (that is, the larger it is to, the faster the change in properties and therefore thinner is the lens).

Referring now to Fig. 3, article 300, the transmission spectrum of a Reactive Mixture, showing the transition region due to absorption 310, overlap with the absorbance spectrum of initiator 340, and emission spectrum of 320 formant, and fixation 330, radiation sources.

The polymerization rate of the polymerization radically mediated by a reactive monomer mixture follows the general velocity equation when the polymerization rate (Rp) is equal to the concentration of reactive functional groups ([C = C]) multiplied by the concentration radical ([•]) and a kinetic parameter (k)

Rp = k [C = C] [^] Equation 3

The concentration of radicals depends largely on the speed of initiation and termination mechanism. Generally, radical-radical / bimolecular termination is the primary termination mechanism. The change in the concentration of radicals over time is equal to the rate of initiation (Ri) minus the rate of termination.

d [-] / dt = Ri - kt [^] 2 Equation 3

Assuming steady state (d [^] / dt = 0), and solving for the concentration of radicals, it is observed that the concentration of radicals varies with the initiation rate at 1/2 power. Therefore, the polymerization rate depends on the initiation rate at 1/2 power.

[•] = (Ri / kt) 1/2 Equation 4

Rp = k [C = C] (Ri / kt) 1/2 Equation 5

When considering the activation energy (E), ideal gas constant (R), the temperature in Kelvin degrees (T), the polymerization speed scaling (p), and the Arrhenius front factor (k0), the velocity of polymerization is expressed:

Rp = koe-E / RT [C = C] (Ri / kt) p Equation 6

The photochemical initiation rate is given by:

Ri = k'I Equation 7

Where I is the intensity of the radiation and k 'is a constant in relation to the quantum efficiency. Assuming that all parameters and concentration of initiator remain constant throughout the reaction, the expression can be simplified so that all parameters that are constant are grouped in k.

Rp = ke-E / RT [C = C] (I) p Equation 8

The polymerization rate is the rate of change of the functional group concentration with time (- d [C = C] / dt = Rp), and therefore the equation can be expressed as:

-d [C = C] / dt = ke-E / RT [C = C] (I) p Equation 9

To the solution of the differential equation and substituting for conversion, where the conversion is expressed as X = 1 - [C = C] / [C = C] or;

X = 1 - exp [-ke-E / RT (I) pt] Equation 10

where t is the exposure time in seconds

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If the Reactive Mixture contains an absorber that absorbs radiation in the wavelength of actinic radiation, the degree of conversion may vary as a function of intensity, and therefore as a function of distance from the surface, according to Beer's Law By inserting the relationship of Beer's Law into the kinetic equation, we can predict the degree of conversion as a function of the distance, x, of the surface.

X (x) = 1 - exp [-ke'E / RT (Ioe'acx) pt] Equation 11

By recognizing that the free form surface will be created at the limit where the degree of conversion is at the gel point (i.e., X = Xgel), the thickness, XThick, of the lens can be predicted by rearranging the equation to solve for x:

ln (1 - Xgei) = kt exp (-E / RT) (Io exp (-acxmck) f Equation 12

image 1

Equation 13

image2

Equation 14

XTh¡ck ~

Equation 16

Xgel is the degree of conversion in which the transitions of the formulation from a liquid to a solid due to the cross-links that are formed during the photo-initiated reaction. After the rearrangement of the equation and solving by XThick to a particular Xgel conversion, the thickness of the film can be calculated. By keeping all other parameters and properties constant a desired thickness at any location x, and on the surface can be estimated by varying the exposure time and time, t. The desired thickness can also be estimated on a voxel basis per voxel where i and j represent the row and column coordinates of a particular voxel and XThicky is the formed thickness of that same voxel.

xmct (** y) = / (/ o (*, y)> '(* »y))

Equation 17

XThickfj ~ / (/ 0 .j ’* ij)

Equation 18

image3

Equation 19

Equation 20

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image4

Equation 23

Equation 24

image5

Equation 25

Typical values for the parameters (Table 1) in the equation can be estimated from the analysis of the kinetic data.

Table 1. Parameters of Equation 14

 Parameter

 Units Value Description

 AND

 kJ / mol. 12.0 Activation energy

 R

 J / K mol. 8.31451 Constant Gas

 T

 ° K 333 Temperature

 k

   1.3 Constant rate

 Xael

   0.2 Conversion to gelation

 P

   0.5 Kinetic factor

 I0

 mW / cm2 10 Intensity

 to

 um-1 1.3 Extinction coefficient

 C

   0.01 Concentration

Using this model and the reference parameters shown in Table 1, a graph of the free-form surface distance is of the irradiated surface as a function of time and intensity (assuming a 20% Xgel) is plotted in Fig. 19. The estimation of a free-form surface distance from the surface of the formation optic surface is represented as 1920, versus the irradiation time 1930. And, these values are shown for the calculation of three different incident intensities 1940. As can be clear from the discussion, since the product of this irradiation will be a 1700 Lens Precursor, the distance is an estimate of the 1730 Lens Precursor Form thickness, for a given intensity and the intensity time. After discussion of the previous DLPTM device, since this device functions as a digital intensity control, the time would be related to the integrated time that a mirror element spent in the on state. The intensity that really occurs in a given place of Voxel can be accurately measured by some technique, but the power of the apparatus is that a measurement of the lens product produced from a first pass can be compared with the target thickness, and the difference can be used to lead to a time difference for a particular intensity, referring to the relationship in Fig. 19. For example, if the intensity reaching a Voxel location with the mirror "on" is 10 mW / cm2, then, in reference to Fig. 19 1910, the adjustment that would result from the model can be known by sliding along the curve 1910 to a new thickness target and generating a new time parameter. The control algorithm can use this calculated time objective to adjust the exposure time on each of a

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series of "movie" frames and average quantity that in total is equal to the target time. Or else, the maximum time per frame could be used and then a final intermediate frame could have a fraction of the maximum time per frame and then the remaining frames could have a defined disconnection state. Somehow, the adjusted time may then be used to make a next lens and the process is repeated.

After exposure, the Lens Precursor is removed from the Reactive Mixture reservoir and processed with the fluid chemical removal apparatus, as shown in Figs. 12 and 13. The lens was then stabilized as discussed in the related sections. The lens was then stabilized with a radiating exposure of 420 nm, a point at which the absorber in Etafilcon A, Norbloc, no longer absorbs the incident light significantly. Next, the lens was measured and subsequently hydrated with the aforementioned apparatus.

Real lenses have been made in this way with Etafilcon A, monomer reactive mixture and is measured by its optical power. The measured optical power, in diopters, is presented in the following table for two lenses.

Table 2. Data of manufactured lenses

 Device number

 Optical target power (Diopter) Measured optical power (Diopter)

 one

 -5.75 -5.55

 2

 -5.75 -5.92

In a similar sense, the process conditions were used to make another lens with the same chemical system, Etafilcon A and the lens was measured using a transmitted wavefront interferometer apparatus. In Fig. 4, the difference signal between a formation optics and the lens produced is shown as 400, an assignment of the topography of the lens produced. It is noteworthy that the optical zone of the lens shows the topography thus formed by concentric circular lines 410. The surface is a quality ophthalmic lens device.

In the production of 400 lenses and their measurement, there are characteristics that were designed in the lens and are produced as a figure in the topographic cartography. For example 420, it includes drainage channels programmed in the Precursor Lens Form with low intensity programmed during the exposure of the film. A different type of channel is measured as 440. This article 440 includes a length channel, useful as an alignment mark of the lens surface. This feature is repeated similarly on the other side of the lens and just above the indicated feature 440 to create a clear orientation of the front lens surface, axially, in space.

Table 3. Exemplary parameters for 1 + 2 lens

 Description

 Parameter

 Dosage of Reactive Monomer Mix

 300 uL

 Reactive Monomer Mix

 Etafilcon A

 Reactive Mixture of O2 Monomers

 7%

 Lithography based on ambient Voxel -O2

 7%

 Environment Precursor Processing -O2

 0%

 Training Exhibition to Optics

 102 uW / cm2

 Image Number Sequence

 128 Pictures

 Total Exposure Time

 115 sec

 Coalescence Time - Convex Down

 30 sec

 Wick Effect Steps

 One

 Post Effect Mecha Time - Convex Below.

 60 sec

 Stabilization time

 200 sec

 Fixing Time

 240 sec

 Fixing Intensity to Optics

 4 mW / cm2

 Hydration Fluid

 Dl w / 300ppm Tween

 Hydration Temp

 90 C

 Hydration Time

 15 mm

Example 2

In this section a description of an alternative specific embodiment of an optical forming component 580 is given in Fig. 18 1800. Again, the forming optics is the support on which a Lens Precursor or Lens can build Its representation as 1000, Fig. 10, may be the simplest for this discussion. Fig. 10, in an embodiment already described, may represent a solid mass optics

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substantial 1010, with an optical quality surface formed on it 1011. The alternative embodiment of 1800, discussed here replaced the massive element 1010, with a mold piece 1810, which can be very similar to the mold pieces that commonly comprise the volume of production of standard ophthalmic lenses by current production standards. In such a case, the mold piece may have been formed by injection molding to a standard optical form.

The resulting plastic form could have additional conformation around the optical surface, which is similar to 1011, which comprises a well that surrounds the optical surface 1860. Additional complexity can be derived by forming in the same plastic format, tubes 1850 and 1890 , which can be useful in a fluid flow during the use of the various devices. Similarly, the formation optics could be centered within a larger piece of metal 1840, such as 1040 and its associated elements. In this case, however, the periphery of the molded plastic forming optics could be sealed with a pressure setting between two pieces of metal in a similar way of 1040. The resulting composite device would be useful from this point. to function similar to some 1000 realizations; however, in a single piece that can include both the function of optics 1000 and reservoir 1110 and 1140.

In use, this specimen forms a single piece of the mold, well and clamping apparatus can now be loaded in an equivalent position (around 580 in Fig. 5) in the Voxel 500-based lithography optical system. Some forms The embodiment of this exemplary alternative may include that it has an upper piece of plastic 1830, formed on the formation and well optics. This then defines a volume of space that allows the aforementioned tubes to flow inside.

An alternative embodiment of the Voxel-based lithography optical system may consist in the definition of the light path that comes from a lower place through the optical formation surface 1810, rather than coming from above. This would allow the well around the formation optics to be filled on the internal formation optical surface with the 1870 Lens Formation Reactive Mixture, during an appropriate stage.

Based on the design of the optical formation surface and the desired optical lens characteristics of a series of programmed images can be calculated to irradiate the reactive mixture with the alternative formation optics and well. Reactive mixture 1870 can be filled in the well by some means, at a level that overflows the optical formation surface. The same filling tubes 1850 and 1890 can now flow a passivation gaseous mixture over the top of the lens reactive mixture in the same manner as it did in embodiments 990 and 960. After the stage is performed of irradiation through this embodiment of formation optics, the outlet tube 1890, in the form can be closed by some means at this point, and after the pressure of the inlet gases 1850, can now force the remaining reactive mixture 1870 down the drain 1880. Resulting on the surface of the formation optics can now be an 1820 Lens Precursor, of the type shown in 1700.

From an exemplary perspective, if the Lens Precursor design includes sufficient drainage channels for self-wicking the lens of sufficient Reactive Fluid Lens Blend, then the lens can be allowed to process at a stage of stabilization of the lens. lens in the formed plastic optics, support and well, comprising this alternative embodiment.

By issuing fixation irradiation through the plastic form, the Lens Precursor can be altered to a lens in a similar manner as previously discussed. A metrology step, if you can look through a plastic layer between the lens and the metrology device, could provide the objective characteristics for the desired performance. Flow tubes can now be used to flow aqueous media heated with surfactant through the lens chamber and carry out the hydration, cleaning and removal stage. And, in some embodiments, part or all of the plastic form may include a storage container in which the appropriate storage support is filled as the lens is packaged.

The following is a list of the embodiments that can be claimed:

Embodiment 1. An apparatus for forming an Ophthalmic Lens Precursor, the apparatus comprising: a substrate comprising an arcuate surface, wherein at least a part of the substrate includes an optical quality surface; and a controllable actinic radiation source to cure a portion of a Reactive Mixture of the optical quality surface in a predefined pattern.

Embodiment 2. The apparatus of embodiment 1 further comprising a container for maintaining a volume of Reactive Mixture; wherein the volume of Reactive Mixture contacts the optical quality surface while it is contained within the container and exceeds the volume of the Ophthalmic Lens Precursor. Embodiment 3. The apparatus for forming an Ophthalmic Lens Precursor of embodiment 1, wherein the actinic radiation source includes a light source and the apparatus further includes: a homogenizer positioned to receive light from the light source and provide the light with more uniform intensity than light

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received and where the light with more uniform intensity includes actinic radiation.

Embodiment 4. The apparatus for forming an Ophthalmic Lens Precursor of embodiment 1, wherein the apparatus further includes a spatial light modulator that reflects at least a portion of the light provided by the homogenizer.

Embodiment 5. The apparatus for forming an Ophthalmic Lens Precursor of embodiment 4, wherein the apparatus further includes optics to converge the light reflected by the spatial light modulator.

Embodiment 6. The apparatus for forming an Ophthalmic Lens Precursor of embodiment 4, wherein the substrate includes a mold part comprising a lens forming surface at least partially transmissible for actinic radiation, wherein the mold part is placed to receive actinic radiation from the converging lens system.

Embodiment 7. The apparatus for forming an Ophthalmic Lens Precursor of embodiment 2 further comprising a source of fixation radiation.

Embodiment 8. The apparatus of embodiment 3 wherein the spatial light modulator includes a digital mirror device.

Embodiment 9. The apparatus of embodiment 3 wherein the homogenizer includes a collimator homogenizer.

Embodiment 10. An apparatus for processing an Ophthalmic Lens Precursor, the apparatus comprising: a substrate that supports the Ophthalmic Lens Precursor; a fluid removal device that can be placed to remove fluid material from the Ophthalmic Lens Precursor supported by the substrate.

Embodiment 11. The apparatus of embodiment 10 wherein the substrate includes an Ophthalmic Lens Precursor Formation surface.

Embodiment 12. The apparatus of embodiment 10 wherein the fluid material removal device includes a capillary apparatus and said fluid material removal includes an extraction of the fluid material away from the Ophthalmic Lens Precursor.

Embodiment 13. The apparatus of embodiment 10 wherein the precursor support includes a mold part comprising a lens-forming surface and the apparatus further includes: a housing location where the mold part can be placed where the chemical residue fluid can flow through a near surface region of the Lens Precursor.

Embodiment 14. The apparatus of embodiment 13 further comprising environmental controls to adjust the atmospheric conditions of said housing location.

Embodiment 15. The apparatus of embodiment 14 wherein said environmental controls comprise mechanisms for adjusting one or more of: temperature, humidity, particulates, light and gaseous environment. Embodiment 16. The apparatus of embodiment 10 further comprising a washing system capable of removing the fluid material from said Lens Precursor.

Embodiment 17. The apparatus of embodiment 11 further comprising a source of fixing radiation. Embodiment 18. The apparatus of embodiment 11 further comprising a hydration mechanism to provide hydration fluid to one of: a Lens Precursor and an ophthalmic lens attached to the substrate. Embodiment 19. The apparatus of embodiment 18 wherein the hydration mechanism provides a hydration fluid capable of swelling one of: a Lens Precursor and ophthalmic lens.

Embodiment 20. An apparatus for forming an ophthalmic lens based on a Lens Precursor, the apparatus comprising: a light source capable of emitting actinic radiation; a homogenizer placed to receive light from the light source and provide a more uniform intensity of light than the light received; a spatial light modulator that reflects at least a portion of the light provided by the homogenizer; a converging lens system that converges the light reflected by the spatial light modulator; a mold part comprising a transmissive lens forming surface of sufficient convergent light reflected by the spatial light modulator to comprise actinic radiation; a container for containing the reaction mixture around the lens forming surface in an amount in excess of an amount required to form the Lens Precursor; an operational material removal device to remove the fluid reagent mixture; a housing location where the mold part can be placed such that the fluid chemical residue can flow through the near surface region of the Lens Precursor; and a source of fixation radiation sufficient to fix the unreacted and partially reacted monomer comprising the Lens Precursor to form the ophthalmic lens based on the Lens Precursor.

Embodiment 21. The apparatus of embodiment 20 wherein the mold part includes quartz.

Embodiment 22. The apparatus of embodiment 20 further comprising a discarded light trap.

Embodiment 23. The apparatus of embodiment 20 further comprising environmental controls for locating housing said environmental controls capable of increasing or decreasing one or more of: temperature, humidity, particulate, light, and gaseous environment.

Embodiment 24. The apparatus of embodiment 20 which additionally includes a capillary apparatus capable of removing the fluid material away from the Ophthalmic Lens Precursor.

Claims (12)

5 10 fifteen twenty 25 30 35 40 Four. Five fifty 55 60 65 1. An apparatus for forming an ophthalmic lens based on a Lens Precursor (1700), the apparatus comprising: a light source (520) capable of emitting actinic radiation; a homogenizer (530) positioned to receive light from the light source and provide a more uniform intensity of light than the light received; a spatial light modulator (510) that reflects at least a portion of the light provided by the homogenizer (530); a converging lens system that converges the light reflected by the spatial light modulator (510); a mold part (580) comprising a transmissive lens forming surface of sufficient light convergent reflected by the spatial light modulator (510) to comprise actinic radiation; a container (590) for containing reactive mixture around the lens forming surface in a amount in excess of an amount required to form the Lens Precursor (1700); a housing location where the mold part (580) can be placed such that the residue Fluid chemical (1745) can flow through the near surface region of the Lens Precursor (1700); Y a fixation radiation source (1460), in addition to the light source capable of emitting actinic radiation, sufficient to fix the unreacted and partially reacted monomer comprising the Precursor of Lens (1700) to form the ophthalmic lens based on the Lens Precursor (1700). 2. The apparatus of claim 1, further comprising an operational material removal device (1210) for removing fluid reactive mixture (1745); 3. The apparatus of claim 1 wherein the mold part (580) includes quartz. 4. The apparatus of claim 1 further comprising a discarded light trap (515). 5. The apparatus of claim 2 further comprising a capillary apparatus capable of removing the fluid material away from the Ophthalmic Lens Precursor (1700). 6. The apparatus of claim 1 wherein the mold portion (580) includes an Ophthalmic Lens Precursor Formation surface. 7. The apparatus of claim 5 wherein said removal of fluid material includes an extraction of the fluid material (1745) away from the Ophthalmic Lens Precursor (1700). 8. The apparatus of claim 1 further comprising environmental controls to adjust the atmospheric conditions of said housing location. 9. The apparatus of claim 8 wherein said environmental controls comprise mechanisms for adjusting one or more of: temperature, humidity, particulates, light and gaseous environment. 10. The apparatus of claim 1 further comprising a washing system capable of removing fluid material (1745) from said Lens Precursor (1700). 11. The apparatus of claim 6 further comprising a hydration mechanism for providing hydration fluid to one of: a Lens Precursor (1700) and an ophthalmic lens (1630) attached to the substrate. 12. The apparatus of claim 11 wherein the hydration mechanism provides a hydration fluid capable of swelling one of: a Lens Precursor (1700) and an ophthalmic lens (1630). image 1 FIG. one image2 FIG. 2 image3 image4 FIG. 3